|Project by jayman7||posted 11-13-2009 04:38 AM||10194 views||44 times favorited||16 comments|
I’m working on a couple of end tables, and I glued up the table tops (16” x 16”) a while ago. The tops started to move and warp a little and weren’t so flat anymore. I decided to build a router sled the other day to get them perfectly flat. The flattest reference surface I have in my shop is my table saw so I decided to utilize that. I glued up some 1/2” MDF strips for the rails since they are a pretty consistent width, and epoxied some rare earth magnets to keep them solid to the table saw top. For the sled I used hard maple to minimize any deflection. I applied wax to all the sliding parts to keep it moving smoothly.
Picture #1: The sled set up.
Picture #2: Rare earth magnets. They’re stuck to the table pretty good at 10 lbs holding power for each magnet. You can see I used blue tape and hot glue to keep the table top immobile.
Picture #3: I brought the 3/4” straight bit just barely below the surface
Picture #4: My whoopsie. I was pretty excited to use the jig that I didn’t bother putting stops on the end of the sled. Needless to say, it fell off and dug into the table top. Luckily it was only the bottom of the table top. :) I promptly glued some stops to the sled before jointing the top of it, but not before it fell off a 2nd time. :D
Picture #5: The end result. It left very tiny ridges at every pass but at least it was perfectly flat.
Picture #6: All it took was a quick sanding of 80 grit on my ROS and it came right off.
I flipped the board over and repeated it for the other side. My largest bit is a 3/4” straight bit so it took about 13 minutes to do one side. I might invest in a 1 1/4 or 1 1/2 straight bit if i end up using it a lot. Good thing about this design is that it takes up very little room in the shop since I use the table saw and not a large panel, and I built it all in an afternoon.