I am considering mounting a router table to the right wing of my TS3650.
Basically just a piece of framed melamine, bolted to the wing and to the
rails. This would allow me to use the TS fence for the router but I am
concerned about the stress this might cause on the rails and wing? Any
First, I don't own a TS3650 so I am talking from memory and a couple of web
sites I have looked at. You might have some reason for concern. I believe
the saw has cast iron wings but they have slots running parallel to the
table edge. Rigid implies the purpose for the slots is to allow clamping of
jigs and featherboards. I suspect they saved weight and material cost too.
Nevertheless, I would think the wings are plenty strong.
Memory and pictures suggest the fence rails are aluminum. While the front
rail looks pretty beefy, there might be concern regarding the back rail. It
might need some help with addition of a piece of heavier extrusion
(angle-iron?) that would have to be incorporated into the entire length of
the rail. You might also be able to add angled supports from the saw base
up to the ends of the rails. I have seen pictures of this on other saws and
it works particulary well with a mobile base. I'm thinking out loud here
and you'll have to make the judgement.
Your post caught my eye because I have gathered parts; and am getting ready
to make this mod to my table saw too.
The main thing about the holes is it makes assembly easy. You can get
3 C clamps in there to align it and hold it while you snug up the
bolts. I have used the holes to get a clamp in there to hold a
diagonal fence for doing raised panels.
You're right, the back rail is really tiny It's also shorter than the
front rail. Also the wings don't have any holes on the outside so
you'll have to drill them yourself. My intention is to remove the
wing when I get around to doing it myself. I'd rather have one
continuous surface on the fence side than the holes in the wing.
I should also say you ought to run a rail or two under the melamine so
it doesn't sag over time.
I have almost the same TS model (older, 27" deep, looks like the same
rails, frame and wheels, etc). I replaced the wing (on the left side
when facing the saw) with a Sears version of a router table extension
(PART 0925351). I was far from happy and ended up with many
modifications to both the fence and aluminum extension. I modified the
dust collection, added a proper miter track to the outer edge, T-track
on the fence, ...
I should have made it from scratch.
If you want to spend some $, you may want to check out the Bench Dog
As for the wing support, I didn't find the rails to be too flexible.
However, it would take some care mounting a home made top to the bolt
slots of the front and back rails (note the aluminum edge components in
both the models I mentioned). If you intend to mount it beyond the
existing right wing, I think it would likely need additional adjustable
support (the Sears version is held by bolts in the rail slots tightened
from below while attempting to get the whole thing in the plane - takes
a few tries).
Can't say about the rails on that saw but I mounted my router in the
framed melamine extension table on my Jet TS (the melamine is 3/4 and
the frame is 1x3 oak).
The melamine and frame have sagged from the weight of the light router
(PC 693) even though the frame is securely bolted on three sides. As
already suggested reinforce the melamine in some way, double it or add
'stretchers' of some sort.
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