This router flattening and tenon sled simplifies the flattening of workpieces too large or problematic to pass through a planer. Measuring 1200mm x 1000mm in overall size, the sled will accommodate the largest of projects, whether live edge slabs, table tops or epoxy resin boards, unrestricted in length. Each heavy duty component has been selected to ensure smooth, precise routing and to deliver the flattest, most consistent surface finish, reducing sanding time at the finishing stage.

The lower and upper rails are engineered from high carbon steel, ensuring exceptional strength, durability and load bearing capacity. At 20mm thick, the upper rails will support the heaviest of routers with no bending or deflection, to deliver a consistent depth of cut every time. The rails feature a chrome-plated finish, providing corrosion resistance and a low friction surface for the slider blocks. Each aluminium slider block features a series of linear ball bearings, shielded from dust ingress, providing smooth, precise travel with zero play. The width of the jig is adjustable in size to suit smaller work surfaces, and when flattening stock longer than the sled, the sled is simply shifted further along until the full working area has been flattened.

At the centre of the sled is the router mounting plate, constructed from strong, 10mm thick acrylic. Universally compatible, the plate will accept routers with a base diameter of up to 185mm, by drilling mounting holes to suit. The plate opening measures 63mm, designed to accept large diameter surfacing bits. The sled will accommodate stock up to 48mm thick, and can be raised in height to take thicker stock by affixing wooden battens to the lower rails.

Four rail stop collars ensure that the sled does not leave the lower rails, and their position can be adjusted to limit the available range of travel. Setting the distance between stop collars will allow the creation of tenons, with the thickness of tenon adjusted by increasing or by decreasing the cutter depth. ©