how do you make a router table base for a 1619 bosch router?

Answer 1

contact bosch,

Answer 2

You need a base mounting plate, first.

Take a look at the pic in this link... - http://www.rockler.com/product.cfm?page=1385&filter=bosch%20router%20base%20table

The blue base plate you see there is what I'm talking about. This one happens to be 1/4" aluminum. I prefer the aluminum myself, because it does not bend under heavy use, like the plastic base plates, leaving you with a more accurately defined edge on your workpiece. You can easily make plexiglass bases (or Lexan), or even aluminum, if you have access to it. Buying one off the shelf like at Rockler will already be pre-drilled at the appropriate locations to mount to the bottom of your router.

Once youve chosen a base plate, you need a table ... if you take a moment to browse Rockler's site, you will see that they have several models ready to ship...and in woodworking mags, you can find plans for router tables/cabinets. You can get very simple or very elaborate. The basic of course, is you need a table material and legs.... you can have a small model that sits on top of an existing workbench (very handy for very small shops, or hobbyists who deal with small parts) or stand-alone models. Ive used both over the years, but prefer to use a larger stand-alone that is higher than most (Im 6'3", and don't like to bend over the router table for great lengths of time, heheheh)
Most table tops are made of particle board... usually at least 1 inch thick. You can get particle board in stock sizes, at 1 1/8" at most places, and can order up to 2". If youre making several workstations, or plan too.. then go ahead and buy a sheet of the 1 1/8" material. If not, then just buy a 3/4" sheet, and glue up two pieces to make it 1 1/2" thick. (You COULD use plywood, but I prefer the smoother surface of the particle board). After you have your core then you should surface it with something... I like to use laminate myself... provides a nice smooth sliding surface for the stock. (If you check the bargain bins of your local building supply store, you might even find a piece of damaged countertop, or one that was returned/undelivered for some reason. You could cut a section out of it, to use as a router table core). One note here... a thicker core is more stable, thats why I don't use just a single layer of 3/4" stock for my worktops.
Once you have a surfaced core, the next step is to simply cut a hole in it for the router base, and put a lip on the edge. I like to have about 1/4" to 5/16" lip for the base to rest on. The depth of the rabbet will of course have to be whatever thickness your router base is.

Now you need something to hold that core up... legs or a cabinet of some sort... like I said.. you can get very simple, or very elaborate, with your design. If you have an uneven floor, then adjustable legs come in handy. You could even mount the thing to a wall, like a shelf if you wanted too, but I prefer to have mine where I can roll it out to the middle of the floor so I can work all around it.

Take the time to look at Rockler's products - theyve got some good products. Especially look at the fences/guides they have available. I was making my own long before those Jessem products became available, hehehe, but theyve obviously given some thought to their designs, and they look good.
You can also look at the December issue of Woodworkers Journal, in which 3 router tables are compared - http://woodworkersjournal.com/

I always enjoy making these types of things for my shop, heheh

Have Fun