Uploaded April 2025 | Updated September 2026, 11 hours ago
Routers were originally designed as hand tools to cut surfaces below by referencing the surface above. Modern routers follow the same principle. But the problem—whether hand tool or powered—is that once the area you need to cut is larger than half the base, it becomes nearly impossible to reach it.
The best solution is to enlarge the surface the router uses as a reference—by building a sled.
On my second channel, I’ve made a simple base that mounts a faceplate flush to the bottom, so you don’t lose router depth. After cutting a recess in plywood, the plexiglass plate drops in and is secured with a few bolts.
To cut large lap joints, I rough out the waste with a circular saw and chisel, then use the sled to clean it up. Once the router is set to its final depth, it glides across and finishes the job.
But cutting below the router also means flattening slabs. We can do that by adding rails to the bottom of the sled, making it easy to plane and clean up large surfaces. I can flatten a 28-inch slab just by moving the sled back and forth, and unlike most flattening jigs, you’re not breaking your back to do it.
Full video → youtu.be/s87o3ZJZBrw
Check out my other channel! → @makethingswithrob
Become a patron! → patreon.com/makethings ←
Huge thank you to my patrons that keep this thing going!
*MAKER TEAM*
Michelle B
Keith Current
William L McNally
Rich Lightfoot
Tutor the Barbarian
Aubrey G.
Nukebert
Sam W.
Aaron Knows DIY
G. Salazar
David B.
Make Things
#MakeThings #mtbitesize
Routers were originally designed as hand tools to cut surfaces below by referencing the surface above. Modern routers follow the same principle. But the problem—whether hand tool or powered—is that once the area you need to cut is larger than half the base, it becomes nearly impossible to reach it.
The best solution is to enlarge the surface the router uses as a reference—by building a sled.
On my second channel, I’ve made a simple base that mounts a faceplate flush to the bottom, so you don’t lose router depth. After cutting a recess in plywood, the plexiglass plate drops in and is secured with a few bolts.
To cut large lap joints, I rough out the waste with a circular saw and chisel, then use the sled to clean it up. Once the router is set to its final depth, it glides across and finishes the job.
But cutting below the router also means flattening slabs. We can do that by adding rails to the bottom of the sled, making it easy to plane and clean up large surfaces. I can flatten a 28-inch slab just by moving the sled back and forth, and unlike most flattening jigs, you’re not breaking your back to do it.
Full video → youtu.be/s87o3ZJZBrw
Check out my other channel! → @makethingswithrob
Become a patron! → patreon.com/makethings ←
Huge thank you to my patrons that keep this thing going!
*MAKER TEAM*
Michelle B
Keith Current
William L McNally
Rich Lightfoot
Tutor the Barbarian
Aubrey G.
Nukebert
Sam W.
Aaron Knows DIY
G. Salazar
David B.
Make Things
#MakeThings #mtbitesize
