Router Table - Sled
Router Table - Sled
Router Table - Sled
TABLE SLED
router Materials
Table Sled
A Platform (1) 111/2 x 15 - 1/2 Ply.
B Fence (1) 158 x 33/8 - 113/8
C Backing Strip (1) 1 /2 x 13 - 3/4 MDF
1
5
D Filler (1) 8 x 58 - 6
E Support (1) 3/4 x 21/2 - 41/4
5
F Handle (1) 4 8 x 61/8 - 3/4 Ply.
G Handle Faces (2) 6 x 4 - 1/4 Hdbd.
Hardware
Packed with features, this sled makes it (1) 3/4" x 3/4" - 6" Steel Tube
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ALUMINUM ANGLE HARDBOARD
Exploded
REINFORCES THICK FACES MAKE THE
ADJUSTABLE HOLD-DOWN HARDWOOD FENCE HANDLE EASIER
SECURES WORKPIECE TO GRIP
View Details
AGAINST THE PLATFORM
OVERALL DIMENSIONS:
15"D x 13"W x 6#/4"H
HARDWOOD
SUPPORT KEEPS
FENCE RIGID
BACKING
STRIP REPLACEABLE MDF
STRIP BACKS UP
THE WORKPIECE TO
PREVENT TEAROUT
PLATFORM IS MADE
STUDDED KNOBS AND FROM DURABLE
ALUMINUM PRESSURE BAR PHENOLIC PLYWOOD
SECURES BACKING STRIP
CROSS SECTION
Platform
MITER GAUGE SLOT ON
THE ROUTER TABLE
To begin building the sled, I started Its a good idea to cut this dado while 1" away from the centerpoint of the
with the large platform. And there the platform is still square. Once the bit and parallel to the miter slot. A
are a couple details worth mention- dado is cut, you can shape the plat- strip of carpet tape will temporarily
ing before you dive into this part. form (Figure 1). fix the position of the miter bar so
The first is the material. I used After shaping the platform, I took you can screw it in place. In Figure
phenolic-faced 12" plywood for the it over to the router table and routed 2, you can see how I used the edge
platform. This tough plywood has a a chamfer on all the top edges of the table and fence to position the
smooth surface thats great for jigs. except for the long side that faces platform. Once this portion is done,
But you can just as easily use stan- the router bit. you can move on to the fence.
dard 12" plywood if you wish. Miter Bar. The sled is guided by
Dado. The other detail that I want
to talk about is a dado that runs
a bar that fits in the miter gauge slot
of the router table. To prevent the
2
across the platform. Its sized to hold platform from contacting a router bit,
a backing strip for the workpiece. I positioned the edge of the platform
1
FIGURE
b.
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a.
building the 3
OVERVIEW
Fence
With the platform of the sled com-
plete, the next section to build is the
fence assembly. This is made up of
four pieces the fence, a backing
strip, a support, and a hold-down
(Figures 3 and 6). The fence also has
a hold-down arm that makes it easy
to secure a workpiece to the sled.
Fence. The main portion of the
fence is a thick, hardwood block.
Actually, its two pieces that are
glued together (Figure 4). In the
lower piece, Icut a square notch
sized to fit the hold-down. Now, it
would have been easier to simply
drill a round hole and use a round
arm on the hold-down. But Ididnt
{ A Square Hole. want the hold-down to rack or twist,
To complete the so Iused square tubing.
hole in the fence Along the front face of the fence
face, first drill out I cut a wide rabbet in the bottom
the waste (top edge. This rabbet provides a space
photo). Then file for the MDF backer strip. (Since these fence with an aluminum face. Its cut starter hole in the aluminum (upper
it flush with strips are designed to get chewed from a section of aluminum angle. I margin photo at left). Then at the
the fence. up, its a good idea to make a bunch trimmed off one side of the angle at workbench, I used a file to clean up
of them at one time.) the table saw so all that was left was the hole (lower photo). The sides of
Aluminum Face. The thick hard- a narrow lip, as shown in Figure 5. the hole in the fence guide the file
wood fence is pretty rigid. But tight- The only trick now is, how do you for a flush fit.
ening the hold-down will exert a lot drill a square hole in the face? The Pressure Bar. There are just a few
of upward pressure, which could answer is an easy, two-step process. things left to do on the fence. From
split the fence body. To prevent this After attaching the face, I took the the cut-off section of the aluminum
from happening, Ireinforced the fence over to the drill press to drill a angle, Itrimmed a piece to lock the
4 5
FIGURE FIGURE
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backing strip in position (Figure
5, previous page). A pair of knobs
6 FIGURE
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MAIL Project Sources
ORDER
SOURCES Most of the hardware for the router
sled came from a local hardware store.
Woodsmith Store
800-444-7527 But the large knob (STT-8T), two small
knobs (STT-2T), and swivel pad (RP-3)
Lee Valley came from Reid. I used an Incra miter bar
800-871-8158 (86N70.40) from Lee Valley to guide the
leevalley.com
sled, but any metal or wood runner will
Reid Supply work. For the platform I used a heavy-
800-253-0421 duty, phenolic-faced plywood (153884)
reidsupply.com from Woodcraft.
Woodcraft
800-225-1153
woodcraft.com
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