Thread: has anyone made a router sled using aluminium extrusion rails?

Originally Posted by Storm2point0

That looks like a similar set up to the take one too. Do you have plans for dust collection too?

I’m definitely keen to follow the progress of the build. Thanks mate.

Will definitely include dust extraction - the best way to keep dust off the tracks is to collect it at the point of production. I've got a few ideas for it that I am kicking around at the moment.

Wheels landed at Sydney International a few hours ago according to the tracking - so hopefully I will receive them early to mid-next week.

That’s good. I’m keen to see the results. Where are you based?


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Originally Posted by Storm2point0

That’s good. I’m keen to see the results. Where are you based?

SE suburbs of Melbourne

Originally Posted by riverbuilder

any decent shop with a cnc router should be able to do that for you.

That is not as easy as it would appear, I offered several comanies with CNC machines ongoing work for at least a year and they were not interested to the point that two of them did not even call me back.

Get some biggish steel angle for rigidity and mount it upside down, wheels on each 45 degree face and no dust problems.

Originally Posted by Chris Parks

That is not as easy as it would appear, I offered several comanies with CNC machines ongoing work for at least a year and they were not interested to the point that two of them did not even call me back.

I tried 5 shops with a cnc. 2 said they would get back to me with a price. They Both said the owner doesn’t want to do it. Not as easy as you’d think.


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Sounds like there might be a market for a slab flattening service!

Originally Posted by Storm2point0

....Not as easy as you’d think....

It isn't. Many a newby flattening a slab ends up with a veneer. Knowing where to take a cut, flip, take another, flip, etc until it's flat is an art. I remember watching Jeff and saying shouldn't you wedge it there, and then he saying, but then you'll take more off here when you turn it over. He was right as usual, done it the way I suggested would have given me a 20mm less slab, you just can't beat experience.

Wheels arrived today, another step closer...

Originally Posted by RSD

Wheels arrived today, another step closer...

That’s good. I’m still super keen!!


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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.

IMG_7785.jpg

Watching with interest!

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.

router table sled.jpg

I also scored a 6 replaceable TCT cutter, from Andrey Taylor 0415 242 465
slab leveling bit.jpg