Rigid Routing Sled

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 clamped down. 

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