Thin but Rigid Coping Sled

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Project by LimeyTom posted 204 days ago 2134 views 27 times favorited 7 comments Add to Favorites Watch

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.

7 comments so far

View toddbeaulieu's profile


389 posts in 1603 days

#1 posted 204 days ago

Love it! It’s easy to make jigs that don’t turn out to be useful, but this looks great.

View HillbillyShooter's profile


4348 posts in 891 days

#2 posted 204 days ago

Very nicely done.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View hoss12992's profile


2461 posts in 491 days

#3 posted 204 days ago

This is really cool and I will def be adding one of these to my shop. Great job and thanks for sharing. Welcome to LJ’s

-- The Old Rednek Workshop

View Mean_Dean's profile


1260 posts in 1746 days

#4 posted 204 days ago

Great looking jig! I love the handle on that thing—definitely no problem keeping a grip on that!

-- Dean

View jumbojack's profile


1149 posts in 1223 days

#5 posted 203 days ago

I dont see a place to mount a sacrificial back up. I fear with out a back up you will experience blowout OR do a very shallow climb cut before the main cut is made, but this is dicey.

-- Made in America, with American made tools....Shopsmith

View LimeyTom's profile


2 posts in 205 days

#6 posted 203 days ago

Good point jumbojack. I could fit another toggle clamp on the left hand side of the handle, but you’re right I am compromised width-wise.

View iminmyshop's profile


104 posts in 592 days

#7 posted 203 days ago

Thanks for posting. This looks like a terrific, safe way to rout small parts.

JumboJack is right about adding a sacrificial backup. This could easily be done by putting the clamp on the opposite side and then screwing a back up onto the surface of the jig that, past the edge of the jig then also extends to the table surface. That would minimize blowout.

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