Router Sled Construction:
I needed a jig to hold material while routing (primarily cope cuts). I looked at a couple commercial units and decided that I could build one that suited my needs. I constructed it with 1/2" Baltic Birch, Formica and Sassafras. I used the same material that was used in the construction of the Router Table "so they would match!"
The Sassafras edge banding is tongue and grove construction. This construction technique helped to stiffen the sled. The miter slot guide is also made from Sassafras; not as hard as oak but suits the task just fine.
The handle has a 3/8x16 threaded hole. I drilled a clearance hole and countersunk the bottom so the screw was below the bottom surface. The miter bar lays right on top of it so it's not visible. I epoxied the screw in place since I couldn't tighten it after the miter bar is installed.
I used double sided sticky tape to attach the miter bar to the sled while I dropped the sled into place. I used the fence to make the alignment parallel [to the fence]. Carefully removing the sled, I finished drilling the pre-drilled holes in the miter bar and screwed it in place.
 Laminate glue up |
 Sled blank |
 Edge banding dry fit |
 Initial parts layout |
 Gluing up edge banding |
 Push Knob Bolt Epoxied |
 Push Knob In Place |
 Miter Bar In Place |
 In use |
 In use |
 Finished |
I pre-drilled the holes for the miter bar, support block and the mounting blocks for the two clamps.
The next step is to attach the cross bar needed to support the piece being routed. It has to be perpendicular to the fence. I installed the sled, layed a small square against the fence and the support to be installed. I finished drilling the pre-drilled holes and installed the screws.
The last step was to install the clamps and their mounting blocks. Again, I finished drilling the pre-drilled holes, mounted the blocks to the sled and then mounted the clamp on the blocks.
Once I tried the unit, I found out that the clamp held the piece to be routed so tightly that the left end lifted up slightly. I will mount another clamp to keep the pressure even.
Last Updated: March 29, 2004