"Toller" wrote in
:


"Jim Yanik" wrote in message
.. .
"Toller" wrote in
:

I am making a router tabletop out of 1/2" corian. The Insert is
3/8", leaving 1/4" of corian. That might be strong enough, but I
sure don't want to chance it. I would like to reinforce the bottom.
I can glue plywood or more corian to the bottom around the cutout
to strengthen it.

Would plywood (1/2"?) be adequate, should I use corian, or
something else? Is epoxy a good choice for the glue, or maybe
polyurethane? Is glue adequate, or should I work some bolts into it
as well?




Glue the entire piece of Corian to a 3/4" substrate,preferably birch
plywood for rigidity;otherwise,the Corian will eventually sag from
the weight of the router.

Epoxy is fine,the right kind,of course.
I'd use West System or System Three and the right filler.

I have a half gallon of Wests just a few feet from my router. Is
there any household product I can use as a filler, or must it be
purchased? I have used sawdust as a filler before, but not in an
application where failure could be hazardous.




West makes several different fillers,one of my favs is fumed silica.
Other fillers are plastic microfibers,chopped glass fibers,phenolic
microballoons,and wood dust. Fibers add strength and crack
resistance,microballoons are for lightweight filler.Fillers are mainly used
for gap-filling and anti-sag or no-drip properties,or for "fairing";filling
in the weave of glass cloth in fiberglassing. Only the fiber fillers add
strength.


System Three's website has a free download of The Epoxy Book,a great guide
on how to use these types of epoxy and fillers.

With wood underlayers,you need to first apply a coat of unfilled epoxy for
the wood to absorb,otherwise you get a glue-starved joint.

IMO,that spray-on contact adhesive for laminates would be the easiest glue
to use.


--
Jim Yanik
jyanik
at
kua.net