![]() Move the sled and router to various parts of the bench (with the power off) to see if the bit catches or slides freely. One way to do this is to plunge the bit until it just touches the bench. ![]() Ideally, you want to set the bit at the lowest part of the bench. Once the rails are in place, the router is dropped into the sled and the bit is plunged down. Fortunately, there is a very cool trick you can employ using string or thin cable. ![]() The only tricky part of this process, if there is one, is making sure the two guide rails are not only parallel to one another but also roughly parallel with the top. The rails can be made from 2×6 construction-grade lumber. The router sled is very easy to make from scrap 3/4″ plywood. A router is placed inside a sled that rides along two parallel rails that are attached to the sides of the bench. The power tool method is very similar to the action of a CNC machine. While some folks truly relish this labor of love, others prefer to delegate this grunt work to power tools. The traditional method for flattening a workbench is to use hand planes and winding sticks.
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