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This project came to a head after I realized the importance of using a Table Saw vs a Miter Saw to make an end grain cutting board. I was set out to create my first end grain cutting board after seeing everyone's awesome creations and after a monumental failure cutting my first glue up into 1 inch blocks 10 inches wide with my miter saw I realized just how much deflection my saw really had. The Blocks glued up and with one flat side laying on the clamps and the others having about a 3/16 of an inch difference from the thinnest piece to the thickest. After reading the Wood Whispers article about planing End Grain I decided I didn't need to ruin my planer and should build a cheap router sled.

Materials are 3/4" MDF, 1×2 1/2" Maple, Oak Scraps, Aluminum Angle from Home Depot and Machine Screws.

This was actually a really easy build and it was a combination of a few difference sleds, such as Kevin's, bues0022's and the simplicity of indychip's.

This will most likely get a few modifications in the future but the way it currently stands it works just as advertised. I will have to experiment with different bits as the straight flute bit left some lines in the final piece even after sanding.

Here is the cutting board.

Look foward to your feedback and comments, Thanks for looking.

Matt

Gallery

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Looks good Matt.
 

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Good looking sled. Looking forward to seeing the cutting board
 

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Nice sled, I like the metal runners. I have a similar sled I use for planning boards that are wider than my 13" planer.
I run all my end grain boards through my planner, safely. All you need to do is mill a piece of 2×4 or other scrap to the same thickness as your board and glue it to the end of the cutting board. I leave it about a 1/4" long at both ends.
This will prevent the end grain from blowing out the back as it goes through the planer. Then trim it off with the table saw.
Just looking at the photo of your sled again.
The boards held with the two Irwin clamps.
Make one of those at least as thick as a slice of your cutting board and glue it on. Long grain of course.
Make shallow cuts it will go through the planer fine.
 

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posting this as a possible cure for your deflection problem. This may not be the cause but just in case. Anyway it is good to know how to align your table saw.
 

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Been there, done that. Posted my router sled a few years back. Your concept of building looks like it would work well. By the way, a bowl bit works best for me.
 

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Nice sled! I like the aluminum rails idea.
 

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To eliminate any deflection, try 80/20 or T Slot extrusions



1"×1" extrusion, deflection characteristics available from manufacturer's Web sites

These will easily hold a 3HP router without deflection and there are linear bearings available.

You can find these extrusions and accessories on eBay or make your own wood bearings as wood slides beautifully on these extrutions. I have built a number of items, like my clamp rack, with these extrusions; not shown on this site as they are not made of wood.
 

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Ignor my original question , did not have my glasses on . Thought that was an X-Y track, now I see the rails are screwed down and not on rollers. I imagine with the adjustment of motor in router base it would have actually qualified for a X-Y-Z capable .
Back in 70's college shop class , we called that design DADO Track Jig , mostly for doing shelf slots in cabinet sides , and Bookshelfs.
 
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