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Shop-Made End Grain Router Sled

By: Erich Lage
Routing End Grain can be a dicey affair — unless you use this Jig

5 18 01 Recently, I was working on a project that required cope and stick doors. To help me rout the end grain cleanly and quickly, I built the jig shown here. 5 18 03 Clean cut. The router jig consists of a plywood base that acts like a sled. A pair of large slots cut into the base of the sled let you easily clamp the workpiece in place. I also screwed on a cleat that accepts a backerboard (see photo above). Finally, I added a handle to easily guide the sled. The jig functions as both a sled and a miter gauge. I clamp the workpiece to the jig and adjust the fence to the proper position for the router bit I’m using. The backerboard helps control chipout and can be replaced as needed. Then, it’s a simple matter of pushing the sled and workpiece past the bit. 5 18 05 The sacrificial backerboard is held in place with a cleat and screws. This allows it to be easily replaced.

Published: May 18, 2023
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