A

rock-solid
support
system
helps you rout rail ¾" dowel 4¾" long
ends that tightly fit
mating stiles. The 7⁄64" pilot hole
large base, dado, 1" deep, centered in bottom
and hold-downs ¼" round-overs
designed into this ¾"
sled accomplish 1"
just that, while the 7½"
Sacrificial
handle and dowel backer strip
keep your hands ¾"
safely away from No round-over
the spinning bit. Toggle
This sled shines clamp
at production-
oriented work— 1"
1"
cutting lots of rails 3¼"
on a regular basis, BASE
4"
for example. Better
yet, make both 3"
for a perfect rout- 17"
ing team.
Build this sled by 4" dado #8 x 2" F.H.
¾" deep 1½" ¾" wood screw
cutting the parts to 2" ¼"
the sizes noted on
the drawing. Make
7 ½" 5⁄32" shank hole, countersunk
several extra on bottom face
sacrificial backer
¾" counterbore ½" deep with a
strips. The backers 5⁄32" shank hole, centered inside and #8 x ¾" F.H. wood screw
create zero-clear- countersunk on bottom face
#8 x 1½" F.H. wood screw
ance supports for
cleaner cuts and
can be easily
replaced after
becoming too
chewed up.
Glue two pieces of ½×7½×17" To cope the end of a rail using into the bit. Just after completing
plywood together face-to-face for the sled, raise the bit ¼" higher the cut in the rail end where
the base. Cut a ¾"-deep dado 4" than if you were cutting the rail shown in the photo, slide the
wide in the 1"-thick base. Create directly on the router tabletop to sled and test piece backward.
the handle and rout ¾" round- accommodate the height of the Doing this prevents destruction
overs along the handle edges sled base. Use the toggle clamps of the sled’s trailing inside edge.
except for the bottom. Screw to secure a scrap piece of stock Check the fit of the joint against
the handle, dowel, and toggle the same thickness as your rails your previously routed stiles,
clamps to the base, making sure firmly against the router-table and adjust the height of the
the screwheads are countersunk fence and backer strip with the bit as necessary before cutting
so they won’t rub against the toggle clamps. Turn on the router your rails.
router top. and ease the sled and workpiece Project Design: Rod Cox, St. Paul, Iowa

DP-00707