Rigid Routing Sled
A routing sled is a great help when coping the ends of rails and stiles. But
I had a problem when I built my first sled. The pressure from the toggle
clamp caused the 1/4-in.-thick sled base to deflect, which messed up the
alignment of the rail-and-stile joints. I solved the problem by adding a board
to the front of the sled,plus two top boards that bridge over my workpiece.
This setup keeps the 1/4-in. base from bending when the toggle clamp is
This story originally appeared in American Woodworker May 2003, issue #100.