What's up, hope everyone is doing well, new guy, first post, be cool, I have a feeling this could go both ways, either someone will point out the obvious and give me a list to order or there might be more to my project, please let me know your thoughts, for some reason I feel like this is really simple but I think I'm missing something, so here I am risking looking like a dumski. Here's a description: Wood slab flattening set up that allows up to 4x8 routing area or even longer length rails, portable would be great, using a router mount that actually allows me to use the plunge router base, router is Bosch MRP23EVS, this would have to be a very beefy system as this is going to be manually pushing a 2in bit through hardwood. Ideally, this is something that could break down into two rails (most likely connected at the ends to keep it square I assume) and could separate from the router gantry type of set-up ( no flex there would be great too), but still be able to get set-up dead level ( some kind of leveling feet on the legs, maybe?) needed over and above the slab already on horses level and ready to go. Oh, and it would be great if it was cheap to achieve with openbuild products, as I'm a small operation. Hope that wasn't too bad, looking forward to hearing from you talented folks, thanks for your input.
There are readily half dozen ways to do this, it all comes down to how much you want to spend and how easy you want it to be to use. How often you plan to use it also probably plays into the equation. On the budget end there's: How to Make a $20 Router Sled. Cheap but not necessarily durable. A more durable upgrade would be revising the vertical edges to V-slot and the flat plate of the bridge to 3/16" or 1/4" aluminum. For something a little more along the lines of what you have in the photo, a couple of 1-1/2" fence posts and some PTFE guide blocks attached to a plywood plate would also provide a fairly economical option. Eliminating the friction of the guide blocks could easily be accomplished with roller bearings similar to this project: https://openbuilds.com/builds/plastic-monstrosity.5353/ If this is something you expect to get a lot of use out of it and want something durable that slides fairly easily, C-beam would offer a reasonable approach. A pair of 1500mm C-beams with double wide gantry plates, wheels, spacers, screws etc, would run about $250. As shown in the image below this approach will also need a couple clip angles and a plate which will add a bit more to the project. This approach also allows for a bit of automation. Adding a motor and lead screw to move the sled for you would be fairly simple. None of the suggestions include what to do with the long side rails as you haven't provided enough information as to your table setup.
Well thanks Rick, I appreciate your input. I'm familiar with the cheap sled set up. I'm using a plywood version now and looking forward to an upgrade, as this will be used often. The c beam looks great and later adding a motor and lead screw would save some sore shoulders that's for sure. As for the table set up, there in lies the challenge, a variety of sizes and shapes end up under the sled, in one session you could go from slabs, let's say 24"x 84"x various thickness, usually 2 1/2 to 4 in, then move to round stumps, let's say 18in high. Having a table that could move up and down would be great eventually, though, I would imagine this thing gets expensive quick. For now, let's say having long rails, connected on the ends, all c beam construction,that can, possibly travel up and down c beams in the corners? Sound reasonable? Ideally there would also be leveling feet at the corners, that should be simple I'm assuming. Otherwise, in my simplistic version, I take the c beam sled, put it on v wheels that slide along angle iron. But that's not as cool! Thanks again man, looking forward to building this. Any distribution in Illinois currently?
Could you make a fixed parallel frame that is level but wide open in the middle to framing that connects the two sides that rests on the floor , or bench (basically two parallel lines). Then mount an adjustable platform that lifts from the floor framing up to whatever height you need? That way you only really need vslot and wheels for the x and y. The z platform could probably be lifted to a fairly accurate height with stepper motors then clamped into position to assist in supporting the weight when you get it to the proper height. Hmmmm... Now I want to build one of these. I would make it so I could mount it on a small utility trailer so I could take it to the site of the lumber if needed.
Actually just build it into the utility trailer, mounting the gantry on the trailer side rails. Then just drop the lumber in the bed of the trailer, raise and shim it at the appropriate carving level, and start making chips.
Had a little time to bring the concept along a bit further. Simple 2x4 and 2x6 shimmable sled shown. Easily customizable for whatever the job requires. Upgrade suggestions would be screw drive for the router carriage with end stops set to reverse motion (ping-pong mode) and adding a hand crank bicycle chain system to pull the gantry lengthwise along the rails. Sketchup file attached so you can take it from here.
This is so simple - love it! what is the mechanism that is holding the router to the C-beam and is that a standard part? thanks
Look up at post #3 above. It's explained there. The double wide gantries are stock but the angles and plate would have to be created by the user.
Hey guys, I found this post in searching and this is an awful lot like what I am looking to do. Unless I could get a complete parts list and do it all at once upfront, I was imagining I would start with a manual sled and then add the stepper motors etc. later. My hope was to go 5 feet wide and 13 feet long, imagining I would probably not be doing much work a size over 4‘ x 12‘. so I have some ideas for you. You mentioned wanting it to be portable, I am vision a pair of rugged sawhorses that have built-in pockets for a couple long horizontal boards or maybe even see channel. This would provide the base you need to be stable on the job site. I have you seen those cool folding ladders that are all over Instagram? They fold onto themselves so they look like a 6 x 6“ block until you push a button and unfold them and they look like a ladder. Maybe you could devise something like that. Anyway, as it pertains to the flattening jig itself, would any size C channel be adaptable to the stepper motor set up? It’s funny, I’m obviously a noob at this but have worked around these things and in factory automation for a long time, just never in the actual hardware building aspect. I know this is a fairly old post but I was wondering if anyone had any progress on this. I want to build one of these soon and would love to share resources Etc. thanks! - Charlie
