Quick & Easy Slab Flattening Router Sled

This slab flattening sled is super easy to make and can be made within a few hours. It will help greatly in your shop by allowing you to flattening boards or slabs with your existing router!

Tools & Materials Used:

• Wood Glue  https://amzn.to/3dVtxsu

• Straight Cut Router Bit: https://amzn.to/3sK2VP2

• Delta 36-725 Table Saw: https://amzn.to/3reIucP

• Miter Saw: https://amzn.to/307gWtW

• DEWALT Cordless Drill: https://amzn.to/3rsJ71T

• Bosch Plunge Router: https://amzn.to/2PqXgPs

• Paste Wax: https://amzn.to/3H1L6De

• F-Clamps: https://amzn.to/2ZXSYV9

• Jointer: https://amzn.to/3GWiJ9o

• Surfacing Bit: https://amzn.to/3CTRIku

• Wood Screws: https://amzn.to/3oQD1J1

I start with a scrap piece of Melamine. I decided to use Melamine for this since it’s extremely flat and stable.

Based on the width of the Melamine, I cut down some scrap 2x4s at my Miter Saw to be the same width.

I then use my jointer to remove the factory roundover from the 2x4s and ensure there is a 90-degree relationship between the bottom and side edges.

I next use a straight edge to double check that the 2x4s have straight edges. This is imperative to the functionality of the sled.

I then use my table saw to cut the opposite side of the 2x4s and ensure they are parallel to the bottom edge that I just jointed.

I then lay out my 2x4s onto the melamine, ensuring the 2x4s are flush to the outer edges of the melamine.

I now apply some wood glue to the bottoms of 2x4s and stick them in place.

I use f clamps to hold the 2x4s in place for the time being, and drill some wood screws through the bottom of the melamine and up into the 2x4s to secure everything in place.

I now cut a solid piece of 3/4” thick Oak hardwood that is the size of my router plate. Ensure that this piece is the same size as your router plate so that the router will not move side to side when working. Cut some additional pieces of 2x4s and glue those onto the outer side of one edge of the Oak piece.

Clamp the 2x4 in place to hold for the next step.

Next, pre-drill some holes through the bottom of the Oak piece and into the 2x4.

After pre-drilling, sink some wood screws into both pieces, securing everything permanently in place.

Now I glue and clamp 2 side pieces of Oak onto the bottom piece of oak. These side pieces will be the outer barrier of the router plate and will keep it from moving side to side.

I now pre-drill through the Oak bottom piece and into the Oak side pieces.

After pre-drilling, I again sink some wood screws into place, ensuring the heads of the screws are flush to the wood.

I now repeat the process of gluing on the other side piece.

I clamp into place, pre-drill, and sink wood screws again for this side.

I install a straight cutting bit into my router and slowly make passes through the bottom piece of Oak. This will create the opening for the surfacing bit to stick through when using.

The last step is to apply paste wax to all areas of wood that will be sliding on other pieces of wood. This ensures the sled will slide freely when using, without any snags or hangups.