has anyone made a router sled using aluminium extrusion rails?

**RSD** · 20th June 2020, 12:12 AM

Originally Posted by Therapy

Years ago I made a router sled using the aluminium rails and other bits and pieces I salvaged from an old M3 Triton workcentre and router table. I put the slab on a bench and clamp the sled over it.

I have used it to flatten a few small slabs and it works OK except sawdust can build up in the rails (which is easily cleared with a vacuum cleaner). However, the length of the rails limits the size of the slabs it can be used on to approx. 600mm long and wide.

Attachment 475714

I'm planning on using one of those trays initially, table will be capable of handling 5000 x 900 slabs, will eventually replace the tray with clear polycarbonate.

**RSD** · 20th June 2020, 12:27 AM

Originally Posted by dai sensei

Been playing with designs again. I wanted sliding bearings on a SHS on its side but then requires the edges to be welded. I don't have the gear to weld aluminium plus I couldn't get the sizes I wanted in Aluminium. I've only got a little MIG so stuck to steel 5mm or less, others may have access to better welders, so could modify this design to suit. It restricts the assemblies from movements in all directions, for small slabs not really an issue, but larger slabs from hybrid materials the router bits love to ride up and over.

Attachment 475749

I haven't quite decided how I'm going to counter ride-up - I think first I will get the basic concept working and then engineer out the extra details.

[QUOTE}I also scored a 6 replaceable TCT cutter, from Andrey Taylor 0415 242 465
Attachment 475750[/QUOTE]
Nice - will be interesting to see what you think of that when you try it

- - - Updated - - -

Originally Posted by dai sensei

Been playing with designs again. I wanted sliding bearings on a SHS on its side but then requires the edges to be welded. I don't have the gear to weld aluminium plus I couldn't get the sizes I wanted in Aluminium. I've only got a little MIG so stuck to steel 5mm or less, others may have access to better welders, so could modify this design to suit. It restricts the assemblies from movements in all directions, for small slabs not really an issue, but larger slabs from hybrid materials the router bits love to ride up and over.

Attachment 475749

I haven't quite decided how I'm going to counter ride-up - I think first I will get the basic concept working and then engineer out the extra details.

I also scored a 6 replaceable TCT cutter, from Andrey Taylor 0415 242 465
Attachment 475750

Nice - will be interesting to see what you think of that when you try it

**Storm2point0** · 4th July 2020, 05:39 PM

Any luck in the build so far? Cheers

Sent from my iPhone using Tapatalk

**RSD** · 4th July 2020, 09:04 PM

Progress has been slowed by the reopening of the economy - suddenly found myself needed again, however Lieutenant Dan & Co are doing their best to bring things to a grinding halt again. Have some make progress time booked in for Thursday though.

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