Router sled

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Forum topic by Bigkahunaranch posted 06-09-2019 06:10 PM 221 views 0 times favorited 2 replies Add to Favorites Watch
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128 posts in 1923 days

06-09-2019 06:10 PM

I am in the process of building something similar to this, only it will be used for cutting dadoes and grooves.
(This one is being used for material flattening.)

I have figured out the track set up, ordered cnc kit from that online auction place, it’s the carrier
I’m having issues with. I’ll be using a Dewalt DW625 plunge router.

I need a way to clamp the router to the carrier ( De Sta clamps ???), but I need it removable to facilitate router bit

Any ideas would be greatly appreciated.


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2 replies so far

View bigJohninvegas's profile


631 posts in 1876 days

#1 posted 06-09-2019 06:31 PM

So my sled is used for flattening, and is made out of mdf.
I remove the plastic base from my dewalt dw618 plunge router and mount the base directly to the carrier.
Anytime I need to change a bit, I remove the router motor from the base. Easy, easy.
Can you remove the motor from the base on a 625?

-- John

View therealSteveN's profile


3033 posts in 988 days

#2 posted 06-09-2019 06:39 PM

The thing about making dadoes, and or grooves, isn’t how to easiest make them, but if whatever size you are making them will be an appropriate fit for the pieces you are placing into them.

Use plywood for an example. Even from the same makers plywood isn’t always the same exact thickness. So you will either have pieces that won’t fit or are too sloppy. Some manufacturers sell router sets for “undersized plywood” but they don’t offer a money back guarantee they will match all plywood’s actual thickness.

Just seems that your building a CNC type machine to make dados is a lot of work, and might not work. There are easier to build jigs, that are about foolproof for dados, and grooves are on edges, so an edge guide on a router is the hand held way to go, but many will use a router table for them.

the exact width dado jig.

Using these jigs it is very important to squeeze the sides tightly to the stock you are duplicating, and keep squeezing while you tighten them down. Failure to do that will get you wildly loose dados.

The dead accurate, truest way to do this isn’t fast. It’s with a table saw, and a dado blade, and requires a number of set up cuts usually to get the groove correct for whatever stock you are inserting into the dado. That hinges completely on making sure all of your stock is the same thickness. With plywood, of the same type it is “normal” to have it all be the same thickness from the same pile. Next month on a different pile is when you see differences. On hardwood that you have prepared, it’s up to you to make sure everything going into a dado is uniform thickness, and you always want to know that size before setting up to make your dado cuts.

-- Think safe, be safe

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