How to Build a Router Sled - The Easiest Way to Flatten your slab

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MATERIALS & EQUIPMENT (affiliate):
2 @ 60"
2 @ 34"
2 @ 32"
2 @ 12"

2 @ 38"

2" Surfacing Router Bit 1/2" Shank: Surfacing Router Bit 1/2" Shank

Tools I use (affiliate):

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Ed Parker
P.O Box 1893
Queen Creek, AZ 85142

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[WolfRidgeWoodworking]

The cost to build this was less than $400. $84 of that was for the shipping. It may be cheaper for you depending on where you live. You may also be able to find the parts somewhere else for less money. I found that tnutz.com was the cheapest for me.

[chipmeister]

This is great man. Thanks for showing us how you put it all together, i appreciate it.

[forster]

This came out awesome! I have been wanting to make a similar one for tabletop use and I will probably do something similar to this with extrusion. I will probably add some sort of handle to the gantry so you can move that with one hand and the carriage with the other pretty easily.

[justin_ray]

Looks like a nice design and definitely budget friendly compared to the commercially available ones.

[stephendonathan]

Great video and work! Looks like one of the better ones I've seen made. Take care and GOD BLESS 🙏!

[bobbysipes]

What i like most about the comments on some of these projects is their lack of negative comments no matter how much of a pain in the ass they are

[JordanWoodwerx]

That came out great Ed, looks like it really glides over the work piece!

[cortlandhunt]

Good job Ed I think I need to upgrade mine. 👍🇺🇸

[rkwatchauralnautsjediparty]

Welp, I can’t say that I’m happy you gave me another reason to buy some more t-slots, but I’ll live. 😂

[csrnibbler]

:O Great find on that aluminum extrusion from tnutz. That is less expensive per inch than what I am currently paying for just regular old t-track from powertec. I might have to buy a bunch of lengths of this stuff for some upcoming jig projects instead of t-track. It's also less expensive than the aluminum "angle iron" that I just picked up from HD to make my own router sled. And the extrusion rails are much prettier.

[georgebrill]

Really nice job. I've been thinking of building one and you gave me some really good ideas. Thanks.

[ronboe]

TOT sled has a feature to lock the travel - no idea how they did that but it seemed to me to be a must have feature. I've always (from the comfort of my chair) been biased to the linear bearing style sleds, but Woodpeckers and yours seem to have some serious advantages. I do wonder how those little wheels are working out. I have some concerns about dust getting in the groove and cause some roughness. Has that been a problem? Going the route of Woodpeckers and using high density plastic (tape or blocks) and have it bear on the top and sides would cure that.

Woodpeckers also modified their sled so that you can insert the router mount at different heights to accommodate different thicknesses. You could "easily" do the same with this set up.
Gotta say, this is the best shop made slab flattener I've seen to date. Many great ideas worth stealing. :^D Thanks for sharing!

[jbenson]

Nice build. I was just thinking that maybe a plexiglass base for the router, instead of wood might make it nice in order to see the work

[morokeiboethia]

Sorry if you stated somewhere in video but are the tracks T-track or V-track?

[GregForLife]

Would love to get an update on how this is working out - my biggest issue with ball bearing shaft units is dust fouling in the bearings. How is this holding up to the sawdust getting in the tracks/wheels?

[shrimpinpat]

You need a wheel on top and bottom
Or get a linear bearing to run the sled on

[morokeiboethia]

Aluminum extrusion looks like crack. You can make so many things and uses out of the stuff and it can be connected in so many ways. I was actually looking into that about a year ago to make an XY track for my crossline laser level but didn't know about the kinds of connectors to buy. There are not many videos at all on the internet showing you how to build with alum-extrus so this was really good to find. How tight are the motion tolerances? For example if I had a crossline laser level and hooked it up to a carriage and then connected the carriage to the track, if I marked where the laser was hitting the floor at 2 different points, then I shifted the laser level and carriage down the track exactly 16 inches then marked again where the laser was intersecting the floor at 2 different points, would the laser lines locations be virtually perfect parallel or is there a little bit of deviation when you slide it along the track?

[kandiecandelaria]

So how much did it end up costing to make?

[evancohn]

Looks fantastic. Just emailed TNuts to see what the whole package costs and to make sure I order all the right stuff. What EXACTLY are the additional screws and nylon washers that you added? Again want to be sure I do this right. Super idea. Curious as to what you come up with for dust collection. The Woodpecker version looks like it does a good job at that. After I get mine built will see what I can come up with also. Thanks

[williamellis]

Looks great, Ed. Definitely better than wood and still budget friendly. Where did all the chips and dust go? I didn't notice too much.
Bill