Mount DeWalt DW621 router to Kreg Precision Router Table insert plate

This weekend I finally had some time to mount my router on router table's insert plate. This router table has been sitting un-assembled since April, 2009. It will take me another weekend to finally get this router table fully assembled.



Here are the steps:

Step 1: Mark the edge of the router base plate that you want to face front with a piece of masking tape

Step 2: Place the insert plate face down on work surface with Kreg logo close to you

Step 3: Position the bull’s eye template so that the concentric rings line up with the opening of the insert plate.

Step 4: Remove the base plate from the router and using it to find the correct drill bit size for drilling holes in the insert plate

Step 5: Place the base plate face down on the bull’s eye template and center it on the concentric rings. Use the masking tape to secure the two together

Step 6: Place a sacrificial board on the drill press under the plate to reduce the possibility of blowout

Step 7: With three items secure, drill the holes using drill press

Step 8: Clamp the insert plate to drill press and drill holes into the insert plate

Step 9: After the holes are drilled separate the three items and using a counter sink bit to counter sink each hole on the top side of the insert plate to accommodate the mounting hardware

Step 10: The screw head should not sit above flush or too far below. I used 20mm long base plate screw to connect the base plate to router

I tried to ensure that the router bit stay at the center of the circular opening of the router table's insert plate. One of the mounting screws hole is on the edge
. I used a 14 mm long screw for this lower height hole.

Resizing the length of machine screws

The 25 mm long M4X0.7 finally arrived this week.




Here are the steps to re-size the screws to 20 mm length:

Step 1: Cut router plate screws to proper length

Step 1a: Gather up the necessary tools and materials
(i) Vice
(ii) Hacksaw
(iii)Marker pen
(iv)File
(v)Foot rule

Step 1b: Measure the length of the Router plate screw needed.

Step 1c: Mark a circle on the screw where it needs to be cut.

Step 1d: Setup the screw in a vice to cut it to proper length

Step 1e: Cut the screws with hacksaw

Step 1f: Measure the length of the cut screws and file the bottom

Step 1g: Test the screws on router