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Marcus Waddell
11-27-2018, 5:54 PM
Hey all,
I’ve seen a number of arguments against Plywood for a router table top and a number of arguments for an MDF/HPL covered top. Typically, it seems that most folks double up on pieces of 3/4” MDF to make a 1-1/2” thick top and then cover in HPL. I’ve a a couple of reports that even the 1-1/2” solution would sag over time if a 3-1/2 HP (aka heavy) router motor is used.
My question is this…has anyone done a combination of 3/4” BB Plywood on the bottom and 3/4” MDF on the top (still covered with HPL) to create a more stable (but still flat) router table top? If so, pros and cons to that idea?
Thanks in advance for the assistance.

glenn bradley
11-27-2018, 6:39 PM
For my latest work bench I wanted to have a longer span without supporting ribs. My previous bench was 4 layers of MDF with adequate support. This time around I used 2 layers of 3/4" BB ply laminated for strength and sag resistance. this was then laminated to two 3/4" pieces of MDF for a dead flat surface. You would want your MDF on top for the same reason. I have MDF work surfaces that were flooded with BLO, allowed to fully cure and then waxed that have seen service for a decade with minimal wear so the HPL is up to you. Use a laminate on both sides, of course. I do not run rough material over the router table so even the thin melamine on my Rockler top is wear free after many years of use.