Router Flattening Sled

by TheAccentPiece

68K41078

Intro: Router Flattening Sled

If you don't have the money or space for a large planer, a router flattening sled is a great option for you to be able to plane large slabs without having to spend too much money to make this. I provide tips on how to build it and obtain a smooth finish, along with a link to the free plans!

STEP 1: Make Your Cuts

Free plans can be found here.

Make all your cuts. I used this circle saw and this track, but you could use a table saw as well.

The bottom of your sled should be the width of the base of your router, plus 1/4". The plans I made fit my router, but you can modify to fit your router.

Cut a rectangle out of the middle of this piece so the bit will fit through. The width of the rectangle should be wide enough for your bit to fit through. I used this bottom cleaning bit. I found it easiest to make this cut by drilling a hole on either end and using my jigsaw to make the remaining cuts.

STEP 2: Assemble the Pieces

Assemble all the pieces according to the plan using wood glue and screws. After assembly, attach these casters to the bottom of the feet.

You can then assemble the whole piece with the bolts, washers, and nuts. The router should now slide freely within the sled.

STEP 3: Plane the Slabs

You can now plane the slabs. A couple tips to get a smooth finish:

  • Go with the grain. This will make a huge difference!
  • Clean your work area often. And debris that the casters roll over will cause the finish to not be as smooth.
  • shim your slab so that it is stable. Shim from all sides, not just one.
  • Wear a mask and eyewear - this will make a ton of sawdust so do your lungs and eyes a favor and protect them.

Now you are ready to plane down some slabs!

60 Comments

Bobcat1966 3 years ago

i want to build a router sled, I looked at the one on your site. Do you have detailed plans, with dimensions..?

efoster6 5 years ago

I have a large slab from an old tree and I have been looking for the insperation to do this for years and your idea is just what I needed thank you

Errol1951 4 years ago

I have started to work on the slab but if it was any harder it would be stone or coal bent one bit already and it got me wondering if it would be easier to use a grinder that's me above just a different user name

krr711 4 years ago

You make excellent lessons for us. I don't know why, when I select Follow, it will not let me but I have followed lots of other people. Be blessed!

UnderwoodMakes 5 years ago

Hi! Very cool idea and instructable!

I had an idea as I was looking through it because of something I've recently taken apart - What if you used the arm of a radial arm saw as your slider? I recently bought a radial arm saw that ended up having a broken motor, and I disassembled it to see how it worked. If you can get the motor out of the carriage on the arm and mount the arm level across your workpiece, you could mount the router in the carriage and make some pretty complex (or simple) cuts.

Again, great instructable! Just brainstorming out loud. :) See attached image for an example of a radial arm saw. The one in the picture is $60 in my area on Craigslist.

TheAccentPiece 4 years ago

Such an interesting idea! did you end up trying this? I'd be interesting to see how it turned out!

UnderwoodMakes 4 years ago

So I bought a Delta-Rockwell radial arm saw from the 1950s or early 1960s, and I'm just now getting the motor up and running (after about a year!). It's actually pretty easy to get the motor assembly out of the carriage on the arm, and I may try to build a platform for my router that will fit in the carriage. I guess I'll have to post an instructable if I do!

I guess, like yours, it would be kind of a "micro-planer/joiner/flattener/thing"! Both would also have the ability to cut an inset/stairstep shape - yours by raising the router sled to the next set of holes on your end pieces, mine by raising or lowering the arm on the saw.

Thanks for the inspiration!

UnderwoodMakes 4 years ago

Hey! No, I never put this together. I haven't had any reason to, but I still think it would work!

TheAccentPiece 5 years ago

Wow this would be super interesting to see! Let me know if you do it!

seamster 5 years ago

Oh my, that's a brilliant idea! I have an old radial arm saw waiting for a new lease on life, and might have to give this idea a go . . Thanks!!

ClayBall 4 years ago

Excellent Idea. This project is on my to-do list. Thanks for this instructable.

woodlouse 5 years ago

Hi, great instructable very clear and concise.
I will definitely be making one of these.
Many thanks for sharing.

GeraldG38 5 years ago

"Clean your work area often. And debris that the casters roll over will cause the finish to not be as smooth."

I would suggest some kind of edge track for the router guide to run on to avoid the debris under the casters issue.

TheAccentPiece 4 years ago

Agreed - I think it would help a lot. If i redesign, I will definitely make rails.

TheAccentPiece 5 years ago

Yes, if i ever make a new one - it will have a design like that!

gbansen 5 years ago

I see in Step #3 your sled design is different?
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