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Is this router coping sled design OK ?

3171 Views 67 Replies 6 Participants Last post by  MiniMe
I watched this video (and many others) and this seemed reasonable and easy so I thought I would build it.
In the below picture, highlighted in blue is my base which is 1/4" thick, three layers, birch plywood (relatively flat)
On top of it I have an 11 layers piece of Baltic Pywood (3/4") and two Bessey STC HH70 toggle clamps . The clamps are an overkill for this sled but they are there on a temporary basis I can remove them and use them where I need (they are installed using insert screws)

To me this design has a flaw and that is that if you are using a thin base (to avoid having to lift the bit too much) the clamps will push the base downward and the base will bend or the base will be pushed upward putting pressure on the screws that connect the base of the sled (blue) to the base of the clamps (purple)

Should the base be much thicker ? I did try to adjust the pressure the clamps put on the piece of wood in order to avoid the base bending but it ends up with the wood that you are routing getting lose

My sled is longer but that is because later I plan to get it up to this design

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Just started designing and gathering materials for my first sled. Using 1/4" G10 for the base. Haven't chosen (or scrounged) a toggle clamp yet, but yours look good. Am also looking at the style with a moveable stop to lock the work pieces on three sides. Thanks for posting.
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