Step 2: Rout the Rails

rolling outdoor grill table routing the rails
Photo: Kolin Smith
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To keep the clamps out of the router's path, angle a rail across the corner of your work surface, its back edge against a piece of scrap to support your straightedge. Clamp the straightedge over both pieces, positioned to allow your router to cut a ¾-inch-wide channel. Chuck a ¾-inch straight bit in the router, and set its depth to inch. Make several passes, adjusting the depth until the rabbet is inch deep. Rabbet the other rail, too.
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    Tools List

    • miter saw
      Miter saw
    • bar clamps
      Bar clamps
    • straightedge guide
      Straightedge
    • router
      Router with ¾-inch straight bit
    • combination square
      Combination square
    • Doweling Jig
      -inch doweling jig. Go to rockler.com.
    • drill
      Drill/driver
    • 3/8-inch drill bit
      -inch drill bit
    • hacksaw
      Hacksaw
    • 1/16-inch drill bit with combination countersink
      1/16-inch drill bit with a combination countersink
    • bevel square
      Bevel gauge
    • circular saw
      Circular saw
    • 1/2-inch drill bit
      ½-inch drill bit

    Shopping List

    1. 1x4 cedar. Get seven 10-footers.

    2. -inch by-2-inch spiral-cut wood dowels

    3. -inch brass wood screws to attach the tabletop slats

    4. 1¼-inch deck screws

    5. -inch aluminum rod Get 34 inches.

    6. ½-inch threaded galvanized rod for the axle (36 inches, 13 threads per inch)

    7. ½-inch galvanized flat washers

    8. ½-inch locknuts (13 threads per inch)

    9. 8-inch-by-1¾-inch lawn-mower wheels

    10. Wood glue