Router Sled Kit – Router Sled for Flattening Large Surfaces

Product detailed description

When the board does not fit through a thickness planer

A solid-wood table top, wide slab or epoxy board often will not fit through a standard thickness planer. Hand sanding is time-consuming and follows the existing unevenness, so it cannot create a reliable reference surface on its own.

The JGC router sled guides the router in a single plane over the entire workpiece. By making a series of shallow passes, you can remove high spots, flatten warping and prepare an even surface for subsequent sanding and finishing.

Working area 770 × 890 mm; longer workpieces can be machined in sections

In a single setup, you can flatten an area up to 770 mm wide and 890 mm long. The 770 mm width is determined by the length of the cross guide shafts and the design of the mounting plate, and therefore represents the actual maximum working width of the sled.

The length of the workpiece, however, is not permanently limited. After machining the first section, you can move the material or the entire jig and continue with the next section of the board. This allows you to use the sled for dining tables, worktops and other slabs longer than 890 mm.

Each time the workpiece or jig is moved, the guide rails must remain in the same plane and the next section must partially overlap the previous one. Accurate alignment prevents a step from forming between the individual sections of the machined surface.

What you can flatten

The router sled is particularly suitable for:

• solid-wood table tops and wide slabs
• laminated and edge-glued panels
• epoxy “river tables”
• worktops, serving boards and cutting boards
• other workpieces that are too wide for a standard thickness planer.

During installation, you can adjust the height of the guide rails to suit the thickness of the workpiece and the plunge depth of the router being used.

Smooth movement in two directions

With makeshift sleds made from wooden profiles, the router may bind during movement and longer guides may deflect. The JGC system therefore uses linear guides with ball-bearing carriages and bearing blocks.

Two supported SBR20 rails, each 1200 mm long, provide longitudinal movement. A cross bridge with two guide shafts measuring 20 mm in diameter and 1000 mm in length moves on four SBR20UU carriages.

The mounting plate with the router moves along the cross shafts. Four SCS20 linear bearing blocks allow the router to move smoothly across the width of the workpiece.

The result is controlled movement along both axes without having to reposition or turn the entire jig while machining a single section.

Transparent mounting plate

The transparent acrylic plate allows you to see the position of the router bit and the surface being machined. This makes it easier to line up the next pass, maintain the overlap between individual paths and check that the router bit does not travel beyond the workpiece.

The space available for the router base measures 160 × 160 mm. The Festool OF 1400 fits within this space.

The shaft collars on the guide shafts serve as adjustable end stops. They define the end positions of travel and help prevent the sled from accidentally sliding off the guides.

Router compatibility

To ensure correct mounting, you must check:

• the dimensions of the router base
• the position of the mounting holes – these can be adapted to the type of router
• the size of the central opening for the router bit being used
• the clearance around the router body and its controls

The manufacturer lists compatibility with the following models:

• DeWalt DW618
• Milwaukee M18 FUEL 1/2"
• Bosch 1617EVS
• Makita RF1101
• Ridgid R22002
• Ryobi R1631K

The mounting holes in the transparent plate must be adapted to the specific router.

Do you have a different model? Send us its exact model designation or base dimensions and we will verify the mounting compatibility with you.

How to achieve a flat result

The resulting flatness depends primarily on the correct setup of the entire system.

1. Secure both lower rails to a flat and sufficiently rigid surface.
2. Check that the rails are parallel and lie in the same plane.
3. Secure the workpiece firmly. If it is twisted, support it so that it cannot move or flex during routing.
4. Set a shallow depth of cut and guide the router along regular, overlapping paths.
5. After creating the first reference surface, you can turn the workpiece over and flatten the other side in the same way.
6. Finally, remove the router marks by sanding.

Several shallow passes reduce the load on the router, limit vibration and generally leave a cleaner surface than one deep cut.

Technical specifications

Type: two-axis router sled for flattening boards
Maximum working width: 770 mm
Working length in a single setup: 890 mm
Maximum workpiece length: not permanently limited; longer boards can be machined in individual sections
Space for the router base: 160 × 160 mm
Guide element diameter: 20 mm
Length of the supported SBR20 rails: 1200 mm
Number of supported SBR20 rails: 2
Number of SBR20UU carriages: 4
Length of the cross guide shafts: 1000 mm
Number of cross guide shafts: 2
Number of SCS20 linear bearing blocks: 4
Number of SK20 guide shaft supports: 4
Number of adjustable shaft stops: 4
Mounting plate material: transparent acrylic
Set weight: 16 kg

Package contents

• 1× transparent router mounting plate;
• 2× cross bridge mounting plate;
• 2× supported SBR20 linear rail, length 1200 mm;
• 4× SBR20UU linear carriage;
• 2× guide shaft, diameter 20 mm, length 1000 mm;
• 4× SCS20 linear bearing block;
• 4× SK20 guide shaft support;
• 4× shaft collar, diameter 20 mm.

Not included in the package

• router;
• surfacing router bit;
• workbench or base board;
• dust extraction equipment.

Important points when working

Flattening a large surface produces a considerable amount of chips and fine dust. Use effective dust extraction and appropriate eye, hearing and respiratory protection.

Before each use, check that the router, guide rails and workpiece are securely fastened. Position the adjustable end stops so that the router bit cannot travel beyond the safe working area.

The router sled creates a flat reference surface but does not replace final sanding. The result is affected by the accuracy of the guide installation, the rigidity of the work surface, the selected router bit, the depth of cut and the way the router is guided.