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Well with all the other projects, the router extension wing I completed probably a year or more ago FINALLY got a workout, and some problems noticed this past couple of days.
#1. While not blatantly obvious, until I used it there was a bit of a dip on the left side of the router insert plate that would cause a profile to be lower on the entry side, and higher on the exit side, which would make for very bad alignments doing things like mitered profiles where the edges need to meet up exactly. The fix was to shim up the base using masking tape. This is a temporary fix. Long term I figure on using counter sunk flat head screws as adjusters in the same vein as the throat plate on my Ridgid sander...
#2. The recently arrived MLCS router table switch works far better than I had hoped. I have it bolted to the right side leg (as you face the fence) through the OEM holes.
#3. The dust collection from the fence works great, however I have nothing going on under the table yet. I have been pondering what to do about that...
#4. When I initially built it, I put the miter track too far from the bit. I routed the slot closer, but needed a second miter track so that I didn't just have an unfilled gap. I added said second miter track, and have already found having 2 tracks here VERY useful...
I have a much larger problem that I am unsure how to deal with. In the middle of the wing, the hardboard is delaminating from the plywood. I need to figure out how to inject and spread glue throughout the void, and then clamp / press it together as it cures.
With all the issues I am having with it, and the lessons I am learning / have learned, I am SERIOUSLY considering scrapping this one, and starting over from scratch with a different design, something a bit more elegant, with better lamination.... However if I can salvage this one and just move on, that is one less project to do... and a few steps closer to getting the other projects done.
When I laminated it, I used 2x4 cauls to sprad the load across the top, it appears that it might not have been enough. Any suggestions on what I could do to make this work? The other thought was to lay some sort of sheet product OVER the lamination, and weigh it down with a bag or two of QuickCrete to act as a sort of press...
#1. While not blatantly obvious, until I used it there was a bit of a dip on the left side of the router insert plate that would cause a profile to be lower on the entry side, and higher on the exit side, which would make for very bad alignments doing things like mitered profiles where the edges need to meet up exactly. The fix was to shim up the base using masking tape. This is a temporary fix. Long term I figure on using counter sunk flat head screws as adjusters in the same vein as the throat plate on my Ridgid sander...
#2. The recently arrived MLCS router table switch works far better than I had hoped. I have it bolted to the right side leg (as you face the fence) through the OEM holes.
#3. The dust collection from the fence works great, however I have nothing going on under the table yet. I have been pondering what to do about that...
#4. When I initially built it, I put the miter track too far from the bit. I routed the slot closer, but needed a second miter track so that I didn't just have an unfilled gap. I added said second miter track, and have already found having 2 tracks here VERY useful...
I have a much larger problem that I am unsure how to deal with. In the middle of the wing, the hardboard is delaminating from the plywood. I need to figure out how to inject and spread glue throughout the void, and then clamp / press it together as it cures.
With all the issues I am having with it, and the lessons I am learning / have learned, I am SERIOUSLY considering scrapping this one, and starting over from scratch with a different design, something a bit more elegant, with better lamination.... However if I can salvage this one and just move on, that is one less project to do... and a few steps closer to getting the other projects done.
When I laminated it, I used 2x4 cauls to sprad the load across the top, it appears that it might not have been enough. Any suggestions on what I could do to make this work? The other thought was to lay some sort of sheet product OVER the lamination, and weigh it down with a bag or two of QuickCrete to act as a sort of press...
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