Aluminum Insert

Installing the Aluminum Insert to your Router

Mounting the aluminum Insert to your router is a pretty simple job. It can be difficult if you do not follow these simple directions. The absolute best way to get a perfect fit is to use your routers base plate as a template.  You will notice in the video that we are showing an acrylic insert, the steps are the same for the aluminum router table insert.

You will need:

Router base plate, drill or drill press, countersink bit, double sided tape

1.  The first thing you need to do is get out your routers base plate and have a look at it. We will work with the router insert plate upside down. You will notice that most (not all) routers attach their base plate to the router by four screws. Most routers are set up to mount to router inserts with 3 screws. After you find out which holes are for mounting the router and which ones are for mounting the insert, flip the base plate over. Take a sharpie and put a reference mark next to the holes you want for the insert. NOTE: Keep in mind the handles on your router, you want the handles to be able to fit inside the router insert perimeter. This allows easy removal when you pull the assembly in and out of your router table.

2.  Now you want to line the base plate up over the router insert so that the center holes are even. ( notice the router base plate is bottom side up and so is the insert) If you have a porter cable style bushing this would be an excellent help. By putting the bushing inside the insert you can line up the center holes exactly. If you do not have the bushing, no problem, take a few minutes and line up the holes as closely as possible.

3.  You will want to double face tape the router base plate to the insert after you are finished centering base plate to the insert. Take your time so you get it right. Also keep in mind where the holes will line up compared to the pre-drilled holes on the deluxe insert. Sometimes you can use them, sometimes not. They were placed there to accomadate many different type routers, but all are not standardized.

4.  When you have the router base plate taped, take it to the drill press and drill right through the holes in your base plate through the insert plate. This will give you perfect alignment. If you don't have a drill press you can use a regular drill.

5.  When finished remove the base plate and chuck up a countersink bit in your drill or drill press.