Router sledge for OF1010, Festool style

[Ostap]

I needed a sledge for my OF1010. First I was planning to build a classical router box, but OF1010 is designed in such a clever way that it can not be put into the box... Router body (the main plunge rod, to be exact) is few mm outside from the shoe. As I also needed full plunge capacity of the router, I had to think more Festool style and turn to aluminium profile for help.

So here is a result, a slege build from 50x30(x3)mm aluminum profile. Two sides are connected with 50x3mm aluminium plates using epoxy. Added also strips of anti-friction tape for less friction and saw-dust-avoidance.

Works like a charm.

 

[blaszcsj]

Nice work! May copy your idea!

 

[Wuffles]

I'd recommend sticking something (or clamping) to the ends for the underside to stop falling off your jig in a moment of madness (similar to what you have on the top). Makes it easier to slide along without too much thought as well.

 

[Holmz]

Epoxy can be good.
The usual failure mode is the pealing of the parts away from each other where it moves from an edge or corner and propagates across.
Therefore a rivet or screw can be used at the corners so that the peel-strength is not the limiting factor.

(It may not be needed in this case)

 

[Ostap]

While building jigs for OF1010, one should take into consideration very low dust extraction port. I used straight plates for connection to keep the height low and not to interfere with vacuum hose. I did not use bolts because of the same reason. Will see if epoxy will hold (works so far).

As suggested by Wuffles, if you have nice parallel rails for the sldege to run on, clamping piece of board or some other scrap to both sides is recommended for better operation.

If I am already in this thread, I thought also to share my "router table" for OF1010. This is not Festool style, just casual. I used 12.5mm coated plywood as a base and routed 5.5mm housing for router into it. Router is attached using steel bars that came with router and clamped into place using wide-head furniture bolts. Mounting and unmounting router takes less than a minute (which is lightning fast compared to procedure of replacing base plate), vacuum hose fits and I loose (only) 7mm of router plunge depth.

Hope it helps someone.

 

[BrianJA]

Great job. I love this idea