Flattening Workbenches and Wide Boards With A Router
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- Опубликовано: 22 май 2012
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The traditional method for flattening a workbench is to use hand planes and winding sticks. While some folks truly relish this labor of love, others prefer to delegate this grunt work to power tools. The power tool method is very similar to the action of a CNC machine. A router is placed inside a sled that rides along two parallel rails that are attached to the sides of the bench. The router sled is very easy to make from scrap 3/4″ plywood. The rails can be made from 2×6 construction-grade lumber. Cheap and simple!
Here are two options for router bits. They have the same specs (1 3/4″, 2-flute straight bits) but the Freud will save you a few bucks:
Amana -- 45453 - amzn.to/2AV03Uk
Freud -- 12-194 - amzn.to/2EAN38o
Perhaps one of the best parts about this jig is that you can re-use it for other things. Have an end grain cutting board that needs flattening, but you don't want to send it through your planer? Have an oddly-shaped natural edge slab that is just too large for your tools? Both situations can be handled with a setup like this. And if you plan on using it a lot, you can get as elaborate as you want with the design of the jig. The version I show you here is stripped down to the absolute basics.
This video is an excerpt from the recent Split-Top Roubo Workbench Guild Build. Join the Guild today to see the entire set of videos and build your own lifetime workbench!
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These type of videos never get old. Thank you so much for help in this.
Seriously, you are a very effective teacher. Speaking as a novice woodworker, I really appreciate how clearly you communicate and I find your videos very helpful. Keep up the great work.
Very nice router sled. I use a similar setup to get everything square with the strings or wires. One difference I use that makes it easy to see when the two wires just kiss is this: instead of using plastic coated wires, I use uncoated wires. Then I use my little 12 volt battery charger with one lead hooked to one side of one of the rails. The other lead goes to the other sides rail wire but there I have a little 12 volt bulb holder with wire leads coming out of it hooked between the battery charger lead and the rail wire. Now when you tap the rail down, as soon as the two wires touch, the little bulb lights up. I have done this getting accuracy down to the thousandths of an inch. Tom
Tom heck of a solution.
Tom Pretty neat trick there !! Thanks
Neat. Seems like you could do the same with a multimeter, and just listen for the auditory beep. :-)
Pardon my ignorance but couldn't you assure that the rails are parallel by simply using a level between the two sides? Is that just not accurate enough?
Shim the "sacrificial" rails away from the work and they are no longer "sacrificial". Great video, Thank You
Marc - just did this project this morning. My dad built a maple bench top & ended up giving it to me. He had provided a written description of this process, but having the video made it very easy to understand & follow along. It ended up great! I think I routed about a 32nd at the best spot, and .52” at the worst.
Thanks for such a great, informational video!
Fantastic video, I will be doing this next week. You have a great way of teaching. Thank you.
Great video. Followed your technique for flattening my bench and it worked perfectly. For the first time in years I can use the bench as it was intended. Thanks!
Thank you for sharing this, it is brilliant. Your whole take on generating a 'Reference Surface' has expanded my mind and opens up some innovative ways of sizing/thicknessing . SUPERB Sir.
Every time I watch one of your videos, I am reminded of how much I suck. Just the way you drop in little reminders allows a somewhat newbie to understand what you are talking about. Doing the things you do is a completely different story. Thank you for taking the time to make these videos. It has helped me so much. Keep them coming. Johnny K
Great instructional video! I'm going to use this method to flatten a half tree trunk for a sitting bench in the backyard. Chainsaw left a very uneven surface. Your explanation is clear and concise. I wish there were more videos of this quality on RUclips. Thank you so much for spending your time to do it.
Thanks for the video, idea for slight improvement, add another narrower board between the rails and the table, attach them to the table or rails so they will be slightly above table top, then route right on over the edge of the table into the these boards. This would prevent possible chip out and you would have no edge clean up at the end.
that thought jumped out at me the instant he hit the rail with the router. great minds think alike, and so do we, lol
But wouldn't the 2 x 6s accomplish the same thing if they are flush to the side of the workbench? It would be a taller surface that the bit would come I to but they would still be keeping the fibers intact at the edge of the bench I would think? Anyway it's a good suggestion.
Excellent share, thank you. I just bought an old, heavy shop workbench with a pretty beaten block top that needs to be taken down about 3/8" and this will definitely help finish it off.
The length is fine, in my opinion. I am new to the tools and the craft. I just bought my first router (old Caftsman) at an estate sale for $10. I appreciate the explanations and demonstrations you presented. Thanks for taking the time to put this 22 minute video together!
Thanks for the fast response! I've been watching your videos for a long time and have found them super helpful and they've got me really excited about getting into woodworking!
Helpful video. I used the Freud bit and the fixture was super easy to build. Great outcome. I also added a sacrificial board on each side inside the rail so I could go all the way across the work piece resulting in no post planning.
Simple idea perfectly explained. That's what I like about your videos, I'm never left not understanding a bit of the process. Thanks.
Ordered my router...starting my sled build this weekend!
Thanks!
I just used this method on my new Roubo workbench top. I was having a terrible time with the hand plane tearing out the wood. This method did the trick. I had a bit of anxiety when doing it, but it all worked great! I did glue on a couple of stop blocks on the bottom of the sled on each end, so it wouldn't accidentally fall off the side board and dig into my top. Thanks!
This is the perfect solution for my situation. I do not have a designated woodworking bench and do everything on my plywood home built tablesaw/mitersaw cabinet. With no confidence in the flatness of my garage floor to support the rails level/parallel in order to router mill my first slab, your method of sacrificial rails clamped to the workbench (saw cabinet in my case) should be THE PERFECT solution!!!
THANK YOU FOR SHARING!
Your video was perfect in timing, amount of information and delivery also. Nice work!
I wish I could have seen this video a lot sooner! I'm in the process of making a work bench out of 2x4's and have already started flattening out the table top surface. I used a electric hand planer to knock down some of the high spots and now I'm using a electric sander to finesse everything out. I ran into the same problem you did with one side in need of some serious planing. I wanted my workbench top to be around 3" thick, but that's not gonna happen. I'm already below that just to make it flat enough to my liking. Thanks for the really cool video!
Very nice and thorough! Thanks for going over every step.
Great use of an “old” trick. Also a great example of how useful mathematics can be. 3 points determine a plane so with two triangles (rail, diagonal) sharing a common side (the rail you selected not to adjust), you are ensuring the fourth point lies on the same plane. I’m going to give this a try today, and I expect to have to play around with picking my reference rail as I have no clue as to which corner is the lowest. Thanks for the inspiration!
This is the first time I came across using the flexible cords to align the rails properly. After seeing that, I became aware of the self inflicted twisting one can be making on any large board when using a sled router. Pure genius (you must be really good in geometry)!!
I love your show man!
thanks for being here.
What a fantastic video, really simple but extremely clever idea, I can't wait to build one and have a go. Thanks.
Just wanted you to know I used your method and wound up with a dead flat surface. Flat as a pancake. I couldn't be happier. Thanks for the great video. Something I added that helped was stop blocks on either end of the bottom side of the sled. This kept the sled from sliding off the rails.
I added a spacer between the rails and the bench top which let me route all the way to the edge. Final change was I used pre primed MDF from Home Depot for the rails. The primed surface is nice and slick for the sled and factory MDF edges are dead straight.
Again great video, this method works folks.
Good video. Love the string technique!
Thanks Bud,
I recently inherited a woodwork bench from my Uncle but it's not flat. I did not know how to get it flat so I watched a good number of videos on how to do it but yours is by far the most simple and easy to follow method. Thank you very much. It means I will not have to travel to my cousins in order to use his planer and jointer once the table is flat..
Regards,
Allyn Hansen
New Zealand.
Very simple and clear explanation. Thanks!
Those sharp square edges on your workbench are satisfying my soul.
What can I say, Excellent concept Well done will definitely using this idea
Thank you for posting this video. I have a new top for my workbench and, because I lack sufficient clamps, it was cupped when the glue dried. I now have a perfect way to flatten the top and save a project gone wrong.
Marc, well done... This was one of your best video's. You really have become a good teacher and videographer- I really enjoy the video's !!
Great video. I mean really well done and super informative. Even I might be able to do this after watching how you did it.
Beautiful work. This took some thinking (taking me down the garden path of optical mounts from Thor Labs and ideas for some custom machining), but a great tool that can obviate the string work is a laser level. Back the laser level off enough to illuminate the insides of both rails, and that should give you an easy way to get the rails nicely coplanar.
Dude, you make awesome instructional vids!!!
Thank you, I have a large solid table top that I want to level, and you just gave me the answer.
WooHoo
I tried it and it worked quite well. I made a Roubo with some construction 2 x 6's. I needed to flatten the top and this took all the hills and valleys out of the pine. I am very pleased with the results.
Fantastic example, great job.
I am a Machinist/Engineer by trade [retired GM]
Your techniques are impressive. Thx for your expertise.
I am thoroughly impressed and hard to dazzle :-)
Thanks for the great video. Very useful information. Concept could be extended to many applications.
Great clip and example
Thanks for sharing
Thank you very much Marc for this enlightenning video. I also see you're a Festool man ! That's all the credit to you for your good taste. I'm aiming at building my own bench pretty soon, having at last found a good copy of the Emmerit vise. Here in Paris I've been using worn-out old benches for decades, so I think it might be time to personalise my own one. In Europe we tend to use beech. I'm actually considering using hornbeam in 3 layers- middle cross graining (?). I'll look you up again soon
Thanks for the nice instruction. I make a butcher block top wood bench but was having trouble flattening. This looks easy enough to do. :)
Just bought that Freud bit, looking forward to flattening a couple of book matched pecan slabs!
WW....
Hi... From the UK... Nicely executed tutorial vid...
Well explained...
Thanks...
Frank...
Марк,привет.Приятно идосадно,что ты перехватил мою задумку.Всё равно хорошо получилось.Молодец! Мне нравятся такие ребята-рукастые и головастые.
Another great video. Thank you paisan.
Great technique! Thanks!
Thank you so much for this video!!
I have learned sooo much by only watching two of your vids!
I have a work bench that really need to flattened in a proper manner. But instead of using the plastic thread as you are using, i think I am going for using a 1 mm fishing thread. It is not that easy to see, but it is hard (so it vill not be pressed together) and can be tightened very hard and does not weight much, so it will keep a very straight line.
Amateur Guitarmaker form Norway.
built this jig after watching your video ,, worked great ,,,,,, thanks
Great video, keep up the good work!
This is exactly what I was looking for. Practical, easy to build, cheap and accurate. Many thanks for sharing!!
I learned a lot! Thanks.
Merci beaucoup, thanks a lot for the advice. Keep the good work
Jean-Marc 'Belgium)
First off let me say I love your stuff! Second, i'm using your exact setup to flatten a large slab of walnut. It works great. The only thing I added is stops to the bottom of my runner that the router slides on. Mine are just clamped on. it's one less thing to worry about the sled falling off the rails. It happened to me. Luckily I had to route enough that I took it out.
Great video (again) !
Nice, I made one out of 1-1/4 uhmw or white plastic, thanks for the idea!!!!
That's a great idea!
Great video, Thanks. So many people on youtube are annoying to listen to but you're not.
the best explained strings hack to make the rails parallel. well done!
I wonder if your workbench now looks thinner on one end, where you removed 1/4" = 6mm or even more as it seemed of the material. of course that wouldn;t matter, as long as the top is flat.
Nice video and methods. Will incorporate several of your ideas in a jig we are building. You got excellent results...hopefully we will as well. Have a good one...
Probably the best use of the phrase "drop the bass" I've heard in a while.
Excellent technique. To eliminate those triangle remnants on the outer edge, attach a 2-3" wide strip of 1/4" hardboard to your rails. Attach the hardboard to the side of the rail that will lay up against the edge of your bench (as a spacer), ensuring the strips are set below the surface of the bench. This allows the bit to completely pass over the surface of your bench.
AZQuadRunner Ninja'd. I suggested the same thing. Glad to know some had the same thought - I should have checked first!
Hey Marc, (and anyone else who feels they can chime in) I love this video and just finished the glue up of my first real workbench top. I'm going to flatten using this method, my Amana bit is in the mail! I was wondering a couple of things. For the sled can I use MDF instead of plywood? Also considering I haven't sanded or applied any finish to the bench do you think it could work to put some screws through the 2 x 6s as clamps instead of using the clamps to support them. I could always clean up the holes in the side of the bench top later... Thanks for any help anyone.
hi marc just wanted to say a huge thanks i received the autograph today its perfect x
I have one of these because I deal with live edge slabs quite a bit. My side rails are made with 8020. They are a 100% flat, light, and have groves to attach your top sled into. Not the cheapest thing, but if you are using it a lot then it is well worth it
Bravo! If I make a new bench, this video will be studied again! 99.99 percent perfect video. I would like to entertain what would happen if you reversed your sled on a test piece to confirm. Very scientific! That's bro!
so good thanks
I have seen videos on people basically planning boards, one side then the next, and it seems to work out just fine. the jig is a little different but the same idea and i plan to try it myself soon.
I shore liked this it was for sure (shure) informative.
It's really just a large straight bit. Although you might find some interesting options under "bottom cleaning bits"
I may have just never noticed the stroboscopic effect on a drill bit before, but I think you captured it perfectly lol...
This is right on time. I have about 4-0 boards i need to flatten :)
Thanks great vedio and information
The voice of sanity. :)
Good Explanation
Hi
I've just watched this video ... along with almost all you video. It was great and very helpful. I have an idea though conserning making the rails parallel. Just use squared piece of wood or aluminum with a lazer pointer mounted on it on one corner. And a 90 degree ruler on the other 3 corners. It will cost nothing.
Stone Coat Countertops has a jig. It's expensive but it gave me a design inspiration. I think they used 80/20 track for theirs but I think you could also use t-track and then mount the t-track on plywood panels to keep them from bowing. Stone Coat uses a caster system to roll along an already flat desk and theirs rolls along the top. You could also make something similar which rolls along the bottom or use rails like you did. The big box stores have steel angle and square stock which is probably pretty straight and maybe those would make even better rails.
My other suggestion is a simple one. I build hot rods for a living, and when I block sand a car I use a dry guide coat (found at your local auto parts store that sells paint). 3M makes the best. I keep a jar of it when I am doing work like this, too. It comes with a soft pounce pad, and is just a dry graphite or charcoal powder. It's a lot easier and quicker to apply over large surfaces than pencils, and is much easier to see. It also sands off easily whereas pencils can embed in softer woods.
great stuff,
absolutely fantastic your a gem x thanks that means a lot to me x
I just watched this video again (as I am laid up in post surgical recovery for a few weeks and am reviewing many videos on this technique) and the thought came to me that if, when you attached the rails to the side of the bench, if you were to put another 2x4 spacer between the actual rails and the workbench, then your router would be able to come fully across the workbench without leaving the little triangles of undone material.
+Loren Dutka
Or even a strip of 1/2" plywood. He also needs guide rails mounted on the sled (outside of and parallel to the 2x6's) so it isn't slip slopping all over like that.
I'm making some counter tops out of old bowling alleys and was just going give them a quick sanding and leave the imperfections for "character". After watching this I think I might just give it a try. (I have extra if I screw it up).
You're very welcome!
oh I like that method!
I like this guy, if not for any other reason than his shirts.
Thank's for the idea, my problem solved finally..
Молодец ! Respekt!
Great explanation I'm going to link you video on my project.
I linked your video on mine . comes out sept 7th
Another great video, Marc!
I do have two suggestions though- since you did ask. ;+)
Can you not place a piece of 2X4 in between the sacrificial rails and the workpiece, just a little bit below the calculated deepest cut (i.e. if the highest corner is 1/2", drop the 2X4 5/8" below the surface) and make the sled just a little wider. This will allow a space for the router bit to run off the sides, not make the 6X's sacrificial, would be easier on the bit, and probably eliminate the triangles.
Have you done an episode on how to build the table/work bench?
Thank You.
The cross hair technique is a good idea. We use it when installing door jambs. Many installers will use jet line. That's that very thin orange string used mostly by ceiling tile installers.
Mark! I am making a new work bench a winter project. I am working on a sled for my plunge base know so I have it, my question is how do you know what set the bit at for cutting depth? Is is the same as setting my plunge router for mortising?
Used this to flatten out three large chopping blocks with 30 years on them. Great trick
Marc I am working on a workbench at home? I do not have a jointer yet. How accurate is a factory plywood edge would that suffice?
You're the first wood worker outside of Canada that I've seen use Robertson screws!!! Smart man!
Ben Buroker i use them all the time. However, I have only a few rudimentary videos and nothing well filmed. I build and make things, I have no filmography skills.
Izzy Swan uses them all the time
Did anyone else hear Marc say (at 6:24) "Drop the bass"?
I think he is a practicing DJ.
He said bass
He said, quite clearly, "Drop the base on top..." as he was dropping the base on top of the sled sides during his glueup. This is how conspiracy theories get started. Though this one is sorta fun.
Marc could I use straight pieces of metal for the rails I attach to my bench?