Affordable DIY router sled kit for flattening end-grain cutting boards.

Published on 05/31/2025•Product Idea Validation / New Product Ideas (Non-SaaS)

Opportunity Identified:

A woodworker is having a tough time with planer marks, especially when trying to flatten end-grain cutting boards. They're experiencing what's often called "planer violence." Commenters agree that planers aren't the best tool for end-grain and suggest alternatives like drum sanders, which can be pricey, or router flattening jigs. While commercial router sleds are available (like Rockler's for around $200), there's a clear interest in a more affordable or simpler DIY solution rather than sourcing individual CNC rails and parts.

Product Suggestion:

An Affordable, Easy-to-Assemble DIY Router Sled Kit for Hobbyist Woodworkers.

This kit would include:

Pre-drilled, accurately machined rails: Made from stable materials like aluminum extrusion, MDF, or high-quality plywood to ensure flatness and easy assembly. Length options could cater to common project sizes, such as cutting boards and small tabletops.
A universal router carriage/base plate: Designed to fit common trim or mid-size routers, possibly with pre-drilled mounting patterns or a template for users to drill their own. The base plate would be made from a low-friction material like HDPE or phenolic.
All necessary hardware: Screws, bolts, and knobs for easy adjustment and assembly.
Clear, illustrated assembly and usage instructions: Aimed at novice to intermediate woodworkers.
Optional: Adjustable height mechanisms or stops for repeatable passes.

Expected Benefit:

This kit would provide a cost-effective (target price significantly below existing commercial sleds, e.g., $75-$125) and accessible solution for hobbyist woodworkers to achieve perfectly flat surfaces on items like end-grain cutting boards, charcuterie boards, and small slabs. It eliminates the need for expensive planers or drum sanders and avoids the complexity of building a router sled from scratch. This lowers the barrier to entry for achieving professional flattening results on challenging pieces.

Origin Reddit Post

r/woodworking

Can't figure out what's causing these vertical lines...

Posted by u/insaneburrito8•05/31/2025

Everything I run with my DeWalt tabletop planer comes out with these lines. I switched my blades out with new ones, and it's still the same.. maybe even worse. My guess is maybe the screws to

Top Comments

u/ProgrammerPast6194

If the planner has those insert axis, or drum sander... or even a cnc or a router flattening jig, then lots of sanding

u/Sufficient_Garlic321

While it requires an outlay of money, a drum sander is very good in this application

u/insaneburrito8

Lines are on the top, so maybe the roller. I'm a novice woodworker, how do I safely check the roller?

u/Downtown_Emu_2282

This should be higher it’s my guess as well

u/permadrunkspelunk

It looks really cool with those lines. Even if that's not what you were going for. I'd stain/ seal that thing and go home and call it a win. If it needs to be smooth sand it after and reapply

u/solarmolarman

Something on the roller or table?

u/AffectionateOkra3490

I learned not to run end grain through the planer the hard way last year. I was taking 1/128” passes and on my very last pass something catastrophic happened. Ripped huge chunks out of my cut

u/Build-it-better123

I’d head to YouTube University and see how to clean your rollers. If the lines still persist, 60 grit on a belt sander is a solid way to send these lines to their grave.

u/RelativeGlad3873

Just as a safety warning, end grain through a planer is usually not a good idea.

u/AffectionateOkra3490

I bought one from rockler. It might be cheaper to get some CNC rails from amazon and a router mounting plate. I use CNC rails with parts of my rockler kit for flattening slabs.

u/Eternal-December

You can buy or build a slab flattening jig for a router

u/davekingofrock

I built one ages ago and it worked pretty well. Rockler makes one now with aluminum rails and a super smooth router carriage rack. It's around $200 but if you make a lot of cutting boards it'

u/wrencherguy

Invest in a thickness sander.

u/KcDee

Im assuming it's your rollers in the planer. I see one of your other comments mentioning you're doing shallow passes because of the end grain. Youre probably not cutting off enough material a

u/Build-it-better123

I run end grain cutting boards through my DeWalt planer each week. I make sure to chamfer or round over the outside edges first. Micro passes and all is well.

u/Mufasa_is__alive

Maybe Drum sander? Although it would probably also require small depth of cut.

u/insaneburrito8

yeah seemed like i could only make very light passes or else it would get really violent. is there another way to make a flat end grain cutting board without it?

u/Recoiltherapy

It's knick's in the blade dude, come on

u/RelativeGlad3873

Drum sander or wide belt, but both are expensive. Slab flattening jig would be the cheap option.

u/DragonDan108

Hand planing. Been working for centuries

u/wgas

Unplug the machine. Raise it all the way up. Look at the rollers. You can turn them by hand. Ruby them with a damp microfiber cloth to clean any debris off. Emphasis on unplug the machine.

u/neologismist_

So, you still have to sand after running through the planer, it’s not a finished surface. That said, running end grain through a planer is asking for extreme drama.

u/randomguy3948

Sanding

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