Levelling large table

We are starting to draw up our router table and need a way to get the top dead-nuts level. The plan is to use 60"X120"X.5" cast aluminum tool plate for the table and a square tubing steel weldment for the base.

Some ideas I've come up with:
1) Put a dam around the top rails of the base. Get the base fairly level and pour low viscosity epoxy on the top beams. Pull the dams off after cure and viola! - a perfectly level surface.
Problem: Even low viscosity epoxy is not very runny. It might not flow out level enough.

2) Put a mess of jacking screws in the top beams to level the table.
Problem: Actually, a mess of problems. I don't have a collimator. Jack screws are a pain. Jack screws don't transfer vibration well enough for the base to absorb it.

2.5) I suppose I could use epoxy to cast the table in place after the jack screws are set. I still need a collimator.

3) Just get the plate close and then flycut it flat with the router head. This is the method used by Multi-Cam and some other manufacturers, but they use phenolic for the table.
Problem: Seems a waste to buy tool plate and then whack off that nice ground surface with a relatively cheap spindle.

Any router table experts care to comment?

Doug Harrison


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