You may have already seen, but I’m working on a kitchen table for my apartment. Part of the discussion last week was how to flatten large slabs without a large planer.
As a follow up to that discussion, I wanted to post my approach to the problem, and how I used the maslow to help solve it.
First, here’s the overall design I drafted in fusion 360:
Next we have the basic dimensions of the jig. I designed it to fit over a set of 24-30in slabs, assembled with 18mm plywood:
I built a new tensioning system that pulls it tighter into the lower corners to improve accuracy, and it seems to working fairly well:
I assembled the sled with a mallet and nail gun, then gave it a quick sanding to smooth out the edges. The two slot joints on the end were pretty tight, so the amount of sanding you need to do may vary.
The smaller sled that rides inside the large sled to keep the router running smooth and stable. However, it is included in the cut files if you are interested. Every router is different, so you may need to adjust the router mounting holes accordingly.
(After a few passes, I removed the smaller sled to get the bit lower in the assembly, but the removal didn’t cause too much of a problem.)
And here it is in action, resting on two 2x6 boards that sit on the sawhorses and then are screwed into the edges of the slab to stabilize everything.
As you can see, I’m using a different router than my maslow one, but this design would work with any routers that are 7" or smaller at the base, including the Rigid R22002.
Router Sled - Flattening Jig Drawings.zip (75.7 KB)
Cut Files-20180603T202505Z-001.zip (4.5 KB)
(Note: The cut files work fine, but something in the g-code I generated was causing the z-axis to raise and re-lower at each depth change, but it only added a few minutes to the cut if that doesn’t bother you)
Hope this proves useful to some of you; have a great week!