|Project by bues0022||posted 12-13-2010 08:03 PM||15137 views||34 times favorited||13 comments|
I have a few projects running right now, and the lumber I purchased for them was rough cut. I’ve never worked with rough cut before, so I never had the problem of planing down to flat wood. I have a planer, but it’s only a 10” – not nearly enough for this 14+ inch wide slab.
It’s made from 3/4” hardwood plywood for the base. The router runs on 1 1/2” angle iron which is lag-bolted into a sanded smooth 2×4. I have oak “runners” that glide along my rails. Rails are some aluminum I-beam levels that I found on sale at Menard’s. Finally, since my rails bring the router too high to plane the boards, I have strips of pine that raise the workpiece up an inch from the plywood. While unintended, it also gives a side notch for chips to go into during routing which keeps the piece a little cleaner. The plywood base is 4’ long, and I can handle a slab about 20” wide.
I was worried about the board moving during routing – it was cupped pretty bad – so I made some “tack strips” to hold the wood in place. Three drywall screws are embedded into a piece of oak with less than 1/16 sticking out. This is pounded into the end-grain, and clamped to the plywood. I can actually lift the entire sled up just from the workpiece – it’s going nowhere! The last picture are the Ash slabs that I finished using this sled (pic #4 is before)
Problems: The router doesn’t slide all that well on the angle iron, if I push laterally too much the router plate starts to rise up the fillet in the inside corner of the angle-iron, the 2×4 sides would be too short if I was working with a thicker slab (couldn’t capture the rails), and the distance between 2×4’s is about 1/32 too big.
Improvements: I have some Teflon sheet with one side treated so it will actually accept double-sided tape. I plan to tape a strip onto the horizontal portion of the angle-iron to reduce friction. Additionally, I plan on gluing a 1/4” strip of wood to the vertical portion of the angle iron making a perfect 90 degree non-filleted corner. I also plan on taping Teflon to that also. Replace the 2×4 with a slightly trimmed-down 4×4 to allow for more vertical height – should I need it. I will also coat my oak runner with teflon, and fill my gap between the 2×4 and the rails with teflon to snug that up a bit. It should be smooth as butter after all of that!
-- Ryan -- Maple Grove, MN