How to work with phenolic when building a router table insert?
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What is phenolic?
“Phenolic sheet is a hard, dense material made by applying heat and pressure to layers of paper or glass cloth impregnated with synthetic resin. These layers of laminations are usually of cellulose paper, cotton fabrics, synthetic yarn fabrics, glass fabrics or unwoven fabrics. When heat and pressure are applied to the layers, a chemical reaction (polymerization) transforms the layers into a high-pressure thermosetting industrial laminated plastic.” – San Diego Plastics, Inc. Phenolic page.
Due to its strength and hardness it is an ideal material for building a router table insert. It will easily with stand the torque a router will exert on it and not break. It is very easily machined with carbide tips tools.
It is a very dark colored plastic like material. By contrasting the router table insert with the router table top, it provides a easy to see warning that you are approaching the danger zone.
Phenolic is an expensive material the going price is about $20 per square foot.
Purchase enough phenolic to build two router table inserts one for small router bits and the other or larger router bits. This will help in the dust collection to reduce the amount of router shavings that fall down on the router. 1/2 inch thick phenolic is strong enough for a router table insert.
Cutting and machining phenolic produces foul smelling fumes. The volatile organic compounds that are released are pretty dangerous for people to breath, according to OSHA. Use a carbon based respirator when machining phenolic to protect your lungs. The cotton or paper based dust masks will not protect you from the fumes. Also use a face shield and hearing protection when cutting the phenolic.
Machine phenolic in a well ventilated workshop. The fumes smell like burning plastic. Open all of the doors and windows and use a box fan to bring in fresh air from outside. If your workshop is in the basement machine the phenolic outside. You don’t want these fumes in your home.
Once your done machining the router table insert out of the phenolic it is safe to handle and harmless to you.
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