|Project by LimeyTom||posted 01-02-2014 03:00 PM||2812 views||28 times favorited||7 comments|
I made this sled a few months ago after getting frustrated with my earlier attempts. Either they were so thin that the jig flexed when I applied the toggle clamp, or the base was so thick that the router bit wouldn’t reach.
Finally I hit on the idea of having a handle which the material passed under to add stiffness. The clamp is mounted as near as possible to the handle so the force is directed along its axis to stop the jig bowing. I did think about having a screw clamp that passed directly through the handle, but this toggle clamp works pretty well.
I also added a sliding fence to keep the wood parallel to the rear fence, and as it turns out this is usually enough to keep the timber in place without the toggle clamp.