Keep in mind that any flexing of the plexiglass will translate into
vibration and wash boarding on the piece of wood your routing. You need
something stiff and solid for a base. Especially if you're using a big
router motor. Auto glass shops and picture framing stores usually sell
plexiglass in small sizes and different thicknesses..
I would be concerned about the plexi flexing under the load of my
3.25HP router. I installed a Rousseau table insert (RM 3509) but
remove the rounter after use. It has two inserts and stabilizing pin.
The table plate is concaved to compensate for the weight of the
router. Installation involved making a rectangular jig to cut the
router table top, using a hand held router.
I have been buying 3/8" cutting boards at Bed Bath and Beyond and making all
my inserts from the plastic material.
It is fairly tru as far as the surface goes, flexs a bit and is easy to work
I make router, table saw and any number of other inserts and some fixtures
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