The router table in my shop is the go-to tool for all kinds of profile and joinery work. With a large table and a fl at fence, it can handle just about any size workpiece. However, one place where most router tables have trouble is routing small workpieces. The problem is large openings in the tabletop and fence can cause a small part to catch or dip in. This can spoil the cut and be unsafe. But that doesn’t mean you need to give up on routing small parts. A simple shop-made sled can help you make top-notch cuts safely.
Basically, the sled holds the workpiece so that it acts like a larger workpiece. The larger size of the sled makes it easier to push the workpiece past the bit. Best of all, the sled keeps your fi ngers well clear of the bit. Stops. The workpiece is captured between stops and then clamped securely to a long base. The stops are adjustable to accommodate a wide range of parts. This way, you can rout the edge of the part or the end. The tapered knobs that lock the stops in position serve as handles to keep your hands clear. I also added some sandpaper to the base to provide extra grip.
To hold the workpiece against the base, I used a toggle clamp. I replaced the small rubber end of the clamp with a wide wood “foot,” as in the detail drawing on the facing page. This added surface area gives the clamp a firmer grip. I also replaced the upper nut with a star knob to make adjusting the height of the foot a quick and easy process.
