"Charlie Mraz" wrote in message
snip
The questions that most concern
me are the details of mounting the router to the top. Is the preferred
method to relieve the underside in the shape of the base? To what
thickness? What about screws? I have had bad luck with flathead screws
pulling right through MDF before. Would a counterbore and panhead screws be
any better? As a point of information, I have read Pat Warner's webpage,
which is very informative, but leaves out several of these small details.
Also, what about provisions for template bushings? I believe the proper
opening is 1 9/16? What about depth/thickness? Any
information/opinion/reference/etc. will be greatly appreciated.

Charlie

Charlie,

Be careful about the saw horse thing. I made my table top about 5
years ago with the intention of building a cabinet when I got around
to it. Still using those saw horse.

I was just doing some work over the weekend and notice that the top
has started to sag. Mine is 2 MDF sheets, laminated on both sides
with Formica. I have an aluminum bench dog plate in mine.

In reference to the screws in MDF, my understanding is the coarser the
better, but after reading some of Pat Warner's articles, I started
tapping holes whenever I went something to stick to MDF (1/4-20 for
most of the things I do).

In Pat's books, he mentions that he likes to fasten his routers
directly to a single 3/4" MDF top and discards them as they warp. He
also uses a Bench Dog lift too.

You can certainly do this, but on a 3/4" top, make sure you support it
well. I'd be concerned about warp. Just a little drop near the bit
is enough to throw off an otherwise perfect rail and stile joint
(DAMHIKT). If you mount is to a top of double 3/4" MDF (1.5" top),
you're going to lose some cutting height unless you recess a hole for
the router (in which case you have the same problem above).

I hate when people give advice without having the experience and I
never hung a router directly to MDF, but in my experience, you have to
make sure this stuff is supported right. I would hang a router to a
scrap piece for a while and see how you fair.

I personally don't need to allow for template guide bushings on the
table top, since I only use bits with guide bearing on the table.

Good luck!

Make sure you post what you do and how it ends up. I'm going on
vacation this week and I'm taking a pencil and paper to design a
proper cabinet. Maybe if SWMBO gets enough sleep (we have 2 young
kids), I might even be able to build this thing when I get home.

Chuck