Thin but Rigid Coping Sled

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Project by LimeyTom posted 01-02-2014 03:00 PM 6623 views 29 times favorited 7 comments Add to Favorites Watch

I made this sled a few months ago after getting frustrated with my earlier attempts. Either they were so thin that the jig flexed when I applied the toggle clamp, or the base was so thick that the router bit wouldn’t reach.

Finally I hit on the idea of having a handle which the material passed under to add stiffness. The clamp is mounted as near as possible to the handle so the force is directed along its axis to stop the jig bowing. I did think about having a screw clamp that passed directly through the handle, but this toggle clamp works pretty well.

I also added a sliding fence to keep the wood parallel to the rear fence, and as it turns out this is usually enough to keep the timber in place without the toggle clamp.

7 comments so far

View toddbeaulieu's profile


842 posts in 3544 days

#1 posted 01-02-2014 03:13 PM

Love it! It’s easy to make jigs that don’t turn out to be useful, but this looks great.

View HillbillyShooter's profile


5811 posts in 2832 days

#2 posted 01-02-2014 05:34 PM

Very nicely done.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View hoss12992's profile


4157 posts in 2433 days

#3 posted 01-02-2014 08:28 PM

This is really cool and I will def be adding one of these to my shop. Great job and thanks for sharing. Welcome to LJ’s

-- The Old Rednek Workshop

View Mean_Dean's profile


6998 posts in 3687 days

#4 posted 01-02-2014 11:37 PM

Great looking jig! I love the handle on that thing—definitely no problem keeping a grip on that!

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View jumbojack's profile


1689 posts in 3164 days

#5 posted 01-03-2014 04:54 AM

I dont see a place to mount a sacrificial back up. I fear with out a back up you will experience blowout OR do a very shallow climb cut before the main cut is made, but this is dicey.

-- Made in America, with American made tools....Shopsmith

View LimeyTom's profile


3 posts in 2146 days

#6 posted 01-03-2014 08:54 AM

Good point jumbojack. I could fit another toggle clamp on the left hand side of the handle, but you’re right I am compromised width-wise.

View iminmyshop's profile


300 posts in 2534 days

#7 posted 01-04-2014 12:46 AM

Thanks for posting. This looks like a terrific, safe way to rout small parts.

JumboJack is right about adding a sacrificial backup. This could easily be done by putting the clamp on the opposite side and then screwing a back up onto the surface of the jig that, past the edge of the jig then also extends to the table surface. That would minimize blowout.


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