First Ever Trim/Palm Router Sled to Flatten Boards

Whether you already purchased one of my Trim Router Sled Kits or you're considering purchasing one, you've come to the right place. In this video I cover how to put the kit and sled together and I might even answer some questions you might have about the kits. I also show how simple it is to use to flatten some boards. Below you'll find links to my website and additional info about the sled kits and where to buy. Also, make to to follow me on IG where I post a lot of updates on current and future products.

00:00 - Intro
00:55 - Starter Kit
1:34 - Essentials Kit
1:54 - What’s Not Included
2:57 - Mounting Options
3:29 - Assemble and Attach the Rod Supports
4:56 - Attach Bearings to the Router Plate
6:27 - Attach the Router Base
6:48 - Mount Sled to the Rails
8:42 - Attach Sled Handles and Shaft Collars
9:30 - Flattening a Board
12:06 - Dust Collection
13:15 - Final Thoughts

Trim Router Sled Kits

Follow me on IG

[johnbarbuto]

This video and subscription warrant a lot more support than they are getting. The video very nicely explains the assembly. And, the video includes some very useful perspectives, such as the bench dog assembly under the router and the commentary on the wood chips. Also, details about assembly order (such as what to tighten, when) are appreciated. Well done!

[Limon-Chris]

Really clean build! It’s awesome seeing trim router sleds getting more attention lately.
I work with a company that makes high-precision linear rails and ball screws — would love to send over some samples if you're ever building a heavier-duty version of this. Just say the word! 👊

[robertkoretsky]

Great video! I found that accurate drilling of the holes in the plexiglass plate that the router is mounted to, to accept the 16 M5 screws that hold the sliding blocks to that plexiglas, is VERY critical if you want the router to slide smoothly. Whatever technique you can deploy to achieve that accuracy is up to you, but the rails that pass by the router have to be parallel as much as possible for the whole range of motion of the router! I did it with a gage between the rails, and backdrilling while the blocks were clamped to the plexiglass and the rails were passed through the blocks.

[elginstallard]

This is absolutely incredible. I didn’t realize you were the first to flatten boards with a trim router, well done!

[johnpatterson]

I shop built a jig like this about 20 years ago. Used it to flatten a laminated hard maple 2-1/2'x8' bench top for my shop. It worked very satisfactorily. I wish I had had this video to work from at that time.

[crossgrainwoodproductsltd]

Breautifully designed and your explanation for assembly is flawless. Nice and consise with the design too. Back before it was "a thing", I designed and built a crosscut sled using the linear rails. The saw sits on a 3/16" plate of aluminum and cuts across as well as length wise. I wanted to make a 9ft jig, but I could not find rails that long without going custom or paying a fortune for them. So I use my diy circular saw and that I made using the Make Things channel's design with conduit and wood. What makes the saw able to cut in either direction is a two plate method using a thinner top plate for the saw that turns on the 3/16th plate. I use a strong spring and steel rod to lift the saw, turn it and the dowel aligns with a hole in the bottom plate and its locked in. That is a very simplified explanation of how the saw plates work because there are many small pieces, screws, and other items involved in its ability to twist in another direction. When designing this, I kept 3 things in mind- 1) It had to be safe so there is no movement in the two plates once locked together (without being overly complicated too). 2) It had to be precise when cutting. 3) It had to be portable without being heavy. This sled can be moved so I can use it outside on nice days and for storage when not in use. I have a VERY small shop and space is at a premium, so I desighed it so it is stored close to the rafters above my workbench. The jig is on a pulley system and lays horizontally when being lifted or lowered. If you know what a bicycle lift looks like, mine is similar to that. I also can stand it on end with a few adjustments and use it like a panel saw for whole sheets of plywood. I dont work with slabs often only because they are very expensive where i live and i design and make items that can be easily shipped. I made a flattening jig when building my assembly table and instead of buying angle iron, I repurposed one of those simple bed frame made out of steel angle iron. It was free on the side of the road and whenever i see one free i grab it up. I have used them for projects with screws and by welding them. The make great tool holders that i screw to pieces of wood that then are added to the french cleat system in the shop. You just have to be able to drill holes into the steel for screws to attach it and for the tools they will hold. Oh, and lots of cutting oil so you dont overheat the drill bits 🙄. They are easily cut with a hack saw, an angle grinder or a meral bandsaw. I have tool holders already to be assembled, i will just have to drill or cut the appropriate holes depending on what they will hold. I also sell premade screwdriver holders, plyer holders and specific tools like angle grinders for mounting to a wall and ones with magnetic strips to their underside for toolboxe drawers and sides of toolboxes all out of free, repurposed materials I find in other's trash on bulk item pickup weeks in surrounding towns and cities.

[gavett]

This is a fabulously detailed description and demonstration! Very impressive. It makes me feel confident like I understand what to do, why you do it, and am inspired to do it!

[CypressVintage]

Clean and affordable kit. Ill check my router model and place my order. Thank you for putting this together.

[alexisherrera]

Excellent! I did something similar using the same linear bearings for axes Y and Z. I used 20mm rods for the X axis to avoid deflection caused by the router's weight. I added an 8mm all-threaded rod in axis Z to increase the depth cut by 1.25mm for each turn. Using a wireless palm router as you did, is a plus because you don't have to deal with the cord.

[nobbyroj]

love your development here. Superb too.
Perhaps somewhere a lock stop can/could be incorporated to save manual drift. Not necessary, but it may help the less experienced.
A most superb and descriptive video.
Total thanks.
Roj

[JohnSimenson]

Great tutorial!
As good or better than any I have seen on any subject!
Straight foreword uncluttered good understandable info.
Thank you
John
(From Wisconsin)

[HuXtheDestroyeR]

Just seen the message about your father. My condolences. Will be ordering one soon.

[bowuf]

So first.. this is fantastic. Nice that you offer the kit that most have to source right angle brackets, wood, etc for. I would ask though.. if you have a full size router option (or if not, might provide one). With that question.. I'd also ask why palm router vs 1/2" shank 2+hp plunge routers like most DIY videos show. I ask because I assume flattening any sort of hard wood would benefit from the heavier bits and much more power. I do understand that the palm router is much smaller, making this faster/easier to be portable, setup, etc.. but I feel like it would take a lot longer to flatten wood with. To each their own.. I bought the rails, collars and a cheap VEVOR 3.25hp plunge router since I doubt I'll use it that often. But the bracket to put the router on to and attach to the Y rails is the issue for me. I may just buy some acrylic (thick) and the L brackets (aluminum) and see what happens.

[michaelharrison]

Good show but I wondered if you can add a duplicator to one side away from handle. That will be your new addition to it.

[brenthowington]

Very nice little kit. I've bookmarked it for later when I'm ready!

[MrCmonReally]

Any plans for offering mounting plates for full size routers? Seems like a larger base with multiple mounting holes would expand your customer base considerably. Great video!

[lPaulSaltzman]

Assembled and ready to go. You do fine work, I am happy I finally purchased the sled. THANKS.

[robbiebritt]

Do you have the dimensions for the boards used for your sled? Also rod lengths? I too have a small shop, and this would be perfect! Will be ordering the essential kit from you soon. Already ordered a router base plate for a mini router table. Excellent work!

[SaintDavos]

Any chance you will add a hose attachment for dust collection?

[DavisMakers-kiij]

A CNC Dust Boot is something I’m going to try.