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06.03.2021Next was to try out the jig to see how well it would work. After cutting a couple of text pieces of wood, I set one into the Coping Sled and clamped it down. As I was running the first piece through the router bit, for some reason sled stopped near the end. I re-ran the piece of wood through the router and it went through the second time fine. I discovered after that the split fence on the router table, the left side had come slightly loose enough that it could prevent the wood from passing, which is likely what happened the Flush Trim Router Bit On Router Table first time.
All it took was a quick tighten on the knob and fence was locked in place again. A good reminder for me to check that fence more often. I checked the first "coped" edge and even though I ran it through twice, it was still perfectly at 90 degrees, but I decided to cut the end off and re-do the cut because, after this was a text piece. The second cut went smoothly and when then I cut the groves in the frames and Best Router Table Coping Sled Kit fitted the coped end to see how it fit.
No surprise, the coping sled did its job and made a perfect fitting joint Copyright Colin Knecht woodworkweb,com. Join Us On:. About WoodWorkWeb. Amazon Store. The plywood sled is complete. If you need more, just make the base wider!
Easy peasy. You can see here the coping sled in action. The woodworker holds the guide against the fence and from right to left smoothly guides the work piece across the router bit. A small scrap of wood can also be used to "back up" the cut between the work piece and the stationary fence. This helps eliminate blowout that can occur as the router bit exits the cut.
This is what my cope cut looks like. You have two parts, the "tongue" that will mate with the groove on the stile and the "cope" that will fit the contour of the inner edge of the stile. Here's the view from the back of the work piece where you can see these two elements more clearly. What if you don't have the plywood scraps to make this jig?
You probably wont want to buy an entire sheet just to make one small jig. Never fear, there's a better and cheaper way! You can use aluminum extrusions to form the base and the two fences.
Note that I purchased these from a company called Misumi links above and the great part is they have tracks built right into them for fastening all the hardware! For simplicity, I used all the same hardware as I did for the plywood sled handles, standoffs, toggle clamp and polycarbonate. The only difference was that I swapped out the tee nuts for sliding tee nuts more below on that. There's really not much work to be done before assembly.
You really just need to drill the holes in the fences to allow bolts to reach the base. You want to mark the hole locations right over the two outside tracks in the base.
Do this for both the stationary rail and the sliding rail. Did you know that you can cut aluminum with regular woodworking blades and drill bits? Its true and that makes this an easy job! You can use a handheld drill for this but a drill press will help you be more accurate.
NOTE: the sliding fence really only needs one hole in the center. OK, everything will be attached using sliding tee nuts. These are different that regular tee nuts because these have a smooth rectangular bottom that can slide in the grooves of the aluminum base! So useful! OK, good news is that all we have to do now is assemble this thing!
First I add the stationary fence. I slide the fence into the tracks in the base. Like before, I square the fence and tighten it down snugly. I then add the clamp to the stationary rail. Your eagle eye might notice that bit of plywood on top of the fence.
You may be asking yourself "I thought I didn't need scraps for this version of the sled"? Well you're right, you don't. But I couldn't decide where I wanted my clamp to go and before I made a bunch of holes in my nice aluminum fence I decided to add some plywood to the top to make it easier to move the clamp if I felt I needed to.
You can fasten the clamp directly to the aluminum fence using regular steel screws just as you would to plywood. Also note that adding the plywood and extra height will cause another challenge for us Best Router Table Coping Sled Memory to solve in a minute or two Now I just add sliding tee nuts to the handles and slide them into place. This is one nice thing about the aluminum version. You can move these handles from one track to another based on where you want the handles located closer or further from the bit.
Now install the standoffs again using a hex nut as a spacer. Add your sliding tee nut next. Then slide them onto the front side of the sled. Next install the polycarbonate guide the same as in the previous sled. First tighten the standoffs and then go back and tighten the cap screws. Here, Best Coping Sled For Router Table Filter though, is a problem. Because I added the extra plywood to the stationary fence, the clamping bolt wont reach the work piece.
But I solved this by using a longer tee bolt. If you don't know what a tee bolt is, it's a bolt that has what looks like a sliding tee nut for a head. It serves the same purpose allowing you to make jigs that have sliding components.
I hope you found these instructions helpful! If you'd like to see more detail, check out this video where I walk step by step through the build! If you enjoyed this tutorial and found it helpful, you can see more of my work in the following places:.
Question 10 months ago on Step I kind of have an idea in my head but I'm curious as to how you went about squaring up the polycarbonate guide? Answer 10 months ago. Put the polycarbonate guide against the router table fence and then put your square against the router table fence and square up the stationary fence on the sled to the router fence. Since the polycarbonate guide is against the router fence it will become square to the stationary fence on the router sled.
Reply 10 months ago. I have same question as ToddW. The polycarb. What did you do to square it up?
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