77+ Woodworking Router Sled Plans Pdf Free Download

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Introduction: The Router Sled – Your Leveling Solution

Are you tackling a project with warped or uneven wood? A router sled, also known as a flattening jig, is your answer. This simple jig allows you to use a router to create a perfectly flat and level surface on workpieces that are too large or cumbersome for a jointer or planer. This DIY guide will walk you through the process of building your own router sled, saving you money and providing you with a versatile tool for your workshop.

Materials and Tools

Before you begin, gather the necessary materials and tools. This will ensure a smooth and efficient building process. Here's what you'll need:

Wood for the base: Plywood, MDF, or solid wood (approximately ¾" thick). The size will depend on the maximum size of workpieces you intend to flatten. A common starting point is 24" x 48".

Wood for the rails: Straight and sturdy pieces of wood (2x4's or similar). These rails need to be long enough to allow the router to travel the full length of your workpiece.

Wood for the router bridge: Similar wood to the base, but wider to accommodate your router base.

Wood Screws: Various sizes for assembly.

Wood Glue

Router with a Flat Bottom Bit: A wide, flat-bottom router bit is crucial for achieving a smooth, even surface.

Measuring Tape

Pencil

Square

Clamps

Drill/Driver

Circular Saw or Table Saw (for cutting the wood)

Sander (optional, for smoothing edges)

Step 1: Building the Base

Start by cutting your base material to the desired size. Remember to consider the size of the workpieces you plan to flatten. Make sure the edges are straight and square using your saw and square. Sand any rough edges to prevent splinters. The base is simply a flat surface where the material you want to flatten will be placed. No additional work is needed on the base material other than making sure the overall size is adequate.

Step 2: Constructing the Rails

The rails are the key to guiding your router across the workpiece. Cut two pieces of wood to the desired length, ensuring they are long enough to accommodate the full travel of your router. These rails need to be as straight and parallel as possible. Attach the rails to the sides of the base, making sure they are parallel to each other and securely fastened with wood glue and screws. Use clamps to hold the rails in place while the glue dries. The distance between the rails should be slightly wider than the base of your router bridge.

Step 3: Building the Router Bridge

The router bridge is the platform that holds your router and allows it to move smoothly across the rails. Cut a piece of wood wide enough to accommodate your router base. Make sure the edges are straight and square. This piece will need to be sturdy enough to support the weight of the router without flexing. Check that the base of your router will clear the rails on the base frame without issue. You may need to add risers between the router bridge and the router base to create enough clearance.

Step 4: Assembling the Router Sled

Place the router bridge onto the rails. It should slide smoothly from one end to the other without binding. If it binds, check the rails for straightness and parallelism. If the bridge is too loose, consider adding shims between the bridge and the rails to create a snug fit. The bridge only needs to slide, if the fit is too tight the assembly will be difficult to use and will not produce optimal results. Once you are satisfied with the fit, place your router onto the bridge.

Step 5: Securing the Workpiece

Now it's time to secure the workpiece to the base of the sled. Use shims, wedges, or other suitable methods to level the workpiece as much as possible before securing it. Secure the workpiece with clamps or double-sided tape to prevent it from moving during the flattening process. It is important to securely hold the material being flattened so that it does not shift or move while the router is in use.

Step 6: Flattening the Workpiece

Set the depth of cut on your router to a shallow amount (1/8" or less is a good starting point). Turn on the router and slowly move the bridge back and forth along the rails, overlapping each pass slightly. Gradually lower the router bit after each pass until you achieve the desired level of flatness. Take your time and avoid removing too much material in a single pass, as this can cause tear-out or damage to the workpiece. It is more efficient to make shallow passes as opposed to trying to cut the material with a deep pass which will likely lead to tearout or the router bit binding.

Conclusion: Enjoy Your Flattened Masterpiece

Congratulations! You've successfully built and used a router sled to flatten your workpiece. This simple yet effective jig will be a valuable addition to your workshop, allowing you to tackle a wide range of projects with confidence. Experiment with different techniques and materials to further refine your skills. Remember to always prioritize safety when working with power tools. Enjoy your newly flattened masterpiece!

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