When it comes to surfacing rough lumber, especially small offcuts that are too short for a planer, traditional methods can fall short—literally. We needed a solution for working with small boards ranging from 4 to 10 inches long and 3 to 6 inches wide.
Enter this custom-built router sled jig with a vacuum hold-down. It’s scalable for larger projects but excels at handling small, stubborn pieces with precision and ease. Read on to discover how this jig can revolutionize your woodworking setup.
Why This Plan Works
- Allows precise surfacing of small pieces not suitable for a standard planer
- Eliminates the risk of workpieces coming loose during surfacing
- Scalable for large projects by adding more vacuum pods and a bigger router
- Vacuum hold-down ensures solid, reliable grip without damaging the material
- Ideal for compact workspaces where industrial planers aren’t feasible
What You Will Need
- Router trimmer (e.g., Bosch 1HP Colt)
- Vacuum pod with built-in venturi
- Air compressor
- Surfacing router bit (1″ diameter)
- 3/4″ plywood (base and sides)
- 1/2″ plywood (router base plate, stop blocks)
- #8 x 1½” and #8 x 5/8″ wood screws
- 1/4″ NPT quick connect airline fitting
- 1/4″ NPT ball valve
Step 1: Choose the Router Trimmer and Bit
We opted for a Bosch Colt 1HP trimmer paired with a 1″ surfacing bit. The jig’s height is based on the router bit’s length and the desired board thickness. Since we needed to plane pieces down to 1/8″, our jig is relatively shallow. Taller jigs are better suited for thicker boards.
Step 2: Remove the Router’s Base Plate
Detach the router’s factory base plate. Use it as a template to mark the bolt hole positions on your new plywood base plate, ensuring accurate alignment.
Step 3: Locate the Center of the Base Plate
Cut a 4″x16″ piece of 1/2″ plywood. Mark the center using diagonal lines from corner to corner. Place the original base plate in the center and trace around it to mark its position on the plywood.
Step 4: Drill Holes for Mounting the Router
Drill a 1¾” center hole for the router bit to pass through freely.
For mounting bolts, use a 1/2″ Forstner bit for the bolt heads and a 3/16″ bit for the shanks.
Step 5: Attach Router to New Base Plate
Use longer bolts (same thread as the original) to secure the router to the plywood base plate.
Recess the bolt heads to avoid interference with the jig.
Step 6: Cut Plywood for Jig Box
Cut 3/4″ plywood for the box, slightly larger than the vacuum pod.
Include a hole for attaching a shop vacuum to remove debris and a 5/16″ hole for the airline to prevent pinching or damage.
Step 7: Assemble the Box
Screw the box’s ends together using #8 x 1½” screws. Avoid glue for easy jig height adjustments.
Attach the sides carefully to maintain evenness, ensuring the jig surfaces the wood evenly.
Step 8: Mount the Vacuum Pod
Secure the pod with #8 x 5/8″ screws. Insert the medium gasket (or largest that fits your material) for optimal suction.
Ensure there’s no gap between the gasket and wood, or suction will fail.
Step 9: Connect the Airline
Attach the pod’s push-fit airline to a 1/4″ NPT fitting. Use a 1/4″ NPT ball valve for on/off control and a quick connect fitting for easy operation between parts.
Step 10: Add Adjustable Stop Blocks
Screw two small 1/2″ plywood blocks to the router base plate’s ends.
These adjustable stops prevent the bit from cutting into the jig sides during use.
Step 11: Test the Jig
Place a board on the vacuum pod, activate the suction, and press the wood down. With the router off, set the base on the jig and check the gap between the base plate and wood for cut depth. Make shallow passes, moving the router into the piece once it’s at full speed. Slow, steady movement ensures precision and avoids bit damage.
Note: Always check depth settings before powering on and ensure all parts are secure to avoid accidents or damage.
Other Details Display
- Router: Bosch Colt 1HP
- Bit: 1″ surfacing bit
- Jig Material: 3/4″ plywood (sides/base), 1/2″ plywood (base plate/stops)
- Fasteners: #8 x 1½” and #8 x 5/8″ wood screws
- Vacuum Pod: Includes 3 gasket sizes (use largest fitting one)
- Airline: 1/4″ NPT fittings, ball valve, quick connect
- Optional: Shop vacuum port (for debris removal)
- Support blocks: For larger pieces beyond vacuum pod size
Summary
Building a router sled jig with vacuum hold-down is a game changer for surfacing small wood pieces.
With the right setup, including a quality router, vacuum pod, and secure jig box, we can plane boards safely and accurately—without risking damage or misalignment.
This router sled jig for small boards is an essential addition to any efficient workshop.
This plan is a contribution by [SeanO29]. Project Via Instructables – Get the PDF Instructions here.
