I decided to build my own router fence out of aluminum which I cut & machined entirely with woodworking tools!
It's time to finish the built-in router table in my new workbench. In order to do that I have to install the safety paddle switch and come up with a fence. The power switch is an absolute must with any router table and, frankly, I should have done this during the original workbench construction.
I made the choice to make my own router fence for no other reason than I wanted to challenge myself. There are lots of great fence options that could work for this table design either as-is or with a simple modification of the T-bolt locations.
2 Great Options to Buy:
JessEM Router Fence - https://amzn.to/3eBu7eo
Kreg Router Fence - https://amzn.to/3zidVq6
My fence design is centered around a piece of angled aluminum (3"x3"x0.188") that I cut down to 30" long. After marking out the locations of the various mounting holes, slots, and dust collection window - I get to work. Now drilling the holes and even cutting the part to length is easy, it's routing the slots and dust collection opening that is the challenging part! I chose to use my router to accomplish this but you could also simply drill a bunch of holes and smooth out the openings with a file. It would certainly take longer but would avoid the scary router part.
Some takeaways I learned: Go slow and avoid "climb-cutting!". Since the aluminum is much harder than wood the router bit will violently kick the part during a climb cut so you want to avoid that. I also found that a conventional straight sided bit worked well. I also experimented with an up-cut spiral flute bit but it did not end up cutting well in this configuration.
Workbench Plan Links:
Versatile Workbench Build Series - https://youtu.be/IuOvWgg11i4
Versatile Workbench Plans - https://etsy.me/3w41jkC
Versatile Workbench Plans (metric): https://etsy.me/39qrNol
Smaller "Shmedium" Version Full Color Plans: https://etsy.me/3aHay1h
Links from the videos (affiliate links help sponsor the channel!):
------------------------------------------------------------------------------------------------------------- 3"x3" Angled Aluminum (3 ft long) - https://www.mcmaster.com/8982K128-8982K256/
Knurled Black Knobs with threads 1/4-20 - https://www.mcmaster.com/6079K14/
Threaded Inserts 1/4-20 x 15mm deep (50-pack) - https://amzn.to/3wXWv0q
Black T-Track (36") - https://amzn.to/36NO3Xd
Black T-Track Screws - https://amzn.to/3eBhwYD
PowerTec T-Bolt/Knob Kit 5/16" (4-pack) - https://amzn.to/3y0hXmU
PowerTec T-Bolt/Knob Kit 1/4" (4-pack) - https://amzn.to/3xVpPWO
110V Safety Power Switch - https://amzn.to/3iyuE1P
Router Fence Dust Port - https://amzn.to/2UEqYUj
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Blue Sharpie - https://amzn.to/3kGO9ru
Center Punch - https://amzn.to/3xVpZNU
Scribe (2-pack) - https://amzn.to/3eHNSkp
Countersink/Chamfer Bit Set - https://amzn.to/3eJZKCl
Metal Countersink Bit Set - https://amzn.to/2TsGvWB
Machinist Square (3-pack) - https://amzn.to/3kF551G
Machinist Ruler - https://amzn.to/3zlHIOY
Incra T-Rule (6-inch) - https://amzn.to/3A42AeN
Woodpeckers T-Squares - https://bit.ly/3x7BXDF
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T-Track Hold Down Clamps - https://amzn.to/3h3Kxh8
T-Bolt & Knob Kit - https://amzn.to/3dnTeRo
T-Track Universal Stop Kit - https://amzn.to/2UckzPn
Featherboards (2-pack) - https://amzn.to/2V4fyZF
PowerTec Router Bit Guard - https://amzn.to/3eHZpA9