Vaughn McMillan
02-28-2006, 9:01 PM
I recently upgraded my table saw with an Incra TS fence system, and in the process of doing so, I added a Rockler router table extension to the table saw. Since this added quite a bit of weight (and even more when I install the new M12V router), I wanted to add some support to avoid stressing the Incra rails. The TS3650 has a nice built-in mobile base, and I move my saw quite a bit, so the additional support needed to move with the saw, without using any additional floor space (which is hard enough to find in my shop). I decided to go with "kickers" that attach to the base of the saw and somewhere around the ends of the TS rails. I also wanted the kickers to be adjustable in length, so I could add or decrease the amount of support they provide. I used a regular ol' fir 2 x 4, so it's not fine woodworking by any means, but at least I used a roundover bit and some BLO. ;)
To adjust the length of the kickers, I ended up using metal turnbuckles, but instead of using them to apply tension, I'm using them the "wrong" way -- more as a spreader than a puller. I made each kicker to be two pieces, with a turnbuckle between the two halves. Stealing an idea from another post I saw here on the Creek a while back, I split each kicker segment and embedded eye bolts into the ends of each kicker section. Here's a shot of one half of one kicker. You can see where I drilled/routed recesses on each half to accept the eye bolt. I made four of these, all assembled with Gorilla glue.
32938
Here's a shot of all the assorted pieces. In addition to a few bolts, nuts and washers, there are two halves for each kicker, a pair of joist hangers from the local hardware store, and a chunk o' 2 x 4 to provide an easy mounting plate for the joist hangers. It's not real clear in this pic, but the threaded portion of the eye bolts sticks out of one end of each kicker half. You can also kind of see I cut the ends of the kickers at an angle, which should make sense in upcoming pics:
32940
I drilled a couple holes in the TS legs to accept the bolts holding the horizontal 2 x 4, and mounted the joist hanger to accept the bottom of each kicker. Here's a shot of one of them:
32945
I also drilled holes in the oak frame beneath the router table top, which is where I bolted the other end of each kicker.
32942
Once it was all assembled, I could tweak the length of each kicker as needed simply by adjusting the length of the turnbuckle.
32941
Right now I've got it adjusted to give just the slightest amount of compression to the turnbuckle. I don't expect to need any more force than that to keep things straight, but the turnbuckles made it very easy to dial in the amount of force being applied to the router table frame, and thus to the TS rails.
As I mentioned earlier, this is not fine woodworking, but maybe someone can steal an idea or two from this and use it to their advantage.
_ Vaughn
To adjust the length of the kickers, I ended up using metal turnbuckles, but instead of using them to apply tension, I'm using them the "wrong" way -- more as a spreader than a puller. I made each kicker to be two pieces, with a turnbuckle between the two halves. Stealing an idea from another post I saw here on the Creek a while back, I split each kicker segment and embedded eye bolts into the ends of each kicker section. Here's a shot of one half of one kicker. You can see where I drilled/routed recesses on each half to accept the eye bolt. I made four of these, all assembled with Gorilla glue.
32938
Here's a shot of all the assorted pieces. In addition to a few bolts, nuts and washers, there are two halves for each kicker, a pair of joist hangers from the local hardware store, and a chunk o' 2 x 4 to provide an easy mounting plate for the joist hangers. It's not real clear in this pic, but the threaded portion of the eye bolts sticks out of one end of each kicker half. You can also kind of see I cut the ends of the kickers at an angle, which should make sense in upcoming pics:
32940
I drilled a couple holes in the TS legs to accept the bolts holding the horizontal 2 x 4, and mounted the joist hanger to accept the bottom of each kicker. Here's a shot of one of them:
32945
I also drilled holes in the oak frame beneath the router table top, which is where I bolted the other end of each kicker.
32942
Once it was all assembled, I could tweak the length of each kicker as needed simply by adjusting the length of the turnbuckle.
32941
Right now I've got it adjusted to give just the slightest amount of compression to the turnbuckle. I don't expect to need any more force than that to keep things straight, but the turnbuckles made it very easy to dial in the amount of force being applied to the router table frame, and thus to the TS rails.
As I mentioned earlier, this is not fine woodworking, but maybe someone can steal an idea or two from this and use it to their advantage.
_ Vaughn