I fiddled with the stand off and on for a few evenings in a row, but could never make it stable enough. The casters were also worn, so trying to roll it would end up with the legs scraping the garage floor in spots, even though they were set to be a high as possible. The table itself wasn't much better...the formica was blistering/bulging in spots, and most of threaded inserts had cracking around them. The plate was missing the pin insert as well.
Rather than spend who knows how much trying to rebuild them, I opted to go a different route. I purchased the basic Rockler router table system locally (the laminate table with plain phenolic insert. I knew it would take some fiddling to get the overarm to work with the stand, but at least the Rockler stand is solid right out of the box.
Surprisingly, it was much easier than I anticipated. Two of the four mounting holes on the overarm u shaped based perfectly lined up with existing holes on the front rail of the base. I bolted it up to those, and flipped the stand over, and drilled two more holes out on the router base to match two on the rear rail.
I then transferred the track rails on the bottom of the old router table to the new table, giving me the ability to slide the top forward and back a bit (obviously the table router will dictate how far).
I also used BuckeyeDennis's ideas of the stop collar and level clamps for the arm mount. This allowed me to set a height that would work for the overarm, and then swing it out of the way when using the table router.
As for pin alignment, I bought a couple of blank inserts for the router plate. I'll use those for the pins. The routers are ever so slightly misaligned front-to-back, but the table can't move closer to the overarm without modification. I may still do that down the road, but the custom inserts should work fine for now.
I already had a nice mobile base, but the Rockler casters would work just as well if you wanted it portable. I've still got some things to do (router switches/speed control, enclosing the cabinet for dust collection, etc), but it's usable now.
I just thought I'd jot down the details in case anyone else is in the same situation. I originally planned to build a custom base and table, but I'd rather spend my time building the fun stuff instead of shop furniture for now.
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