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Router Sled utilizing Track Saw Guide Rails

Designed these parts to use one set of linear rails (short) and track saw guide rails on the long edge to save cost.
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updated March 11, 2025

Description

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Here's a group of parts I modeled and printed to create a router sled and save some $ by only buying one set of linear rails. I had 4 of the 55" (2-110") track saw guide rails, so made this to utilize those as the long rails. 

Models (No supports needed on anything)

  • Cradle - I have the cradle file for the router, and included split part files (A & B) with a dovetail. I printed these files on the side opposite the cut/dovetail, and they fit great. With the bolts and edge cap installed, and mounted to the slide blocks on the rails, it's solid. No need to glue the cradle halves together imo.
  • Cradle Edge Cap - these parts just help tie the cradle together at the slide blocks. Printed this on the outside long edge opposite where it connects to the cradle.
  • Track Feet - These accept the linear rails and ride on the track saw guide rails with 2-629 bearings in each foot. I have split part files (A & B) included, print them on the flat faces opposite the cut/key/keyway. These will need to be glued together after installing the bearings. I used a 5-minute epoxy to do this, and clamped them together until cured. NOTE-I did not save the split part files I printed, so I recreated these A & B parts which should print and fit just like to what I printed originally.
  • Track Feet Pins - These lock the feet and square in place to the linear rails. You'll want to print 4 if only one Track Foot lines up with holes, 8 if both Track Feet line up with holes (or you drill your own), and 4 additional if using the Track Square. Print these upside down on the head.
  • Track Square - The linear rails rack some as you move the sled along the track saw guide rails. I made this file to stiffen the linear rails some to prevent so much racking. It still racks some, but works fine. I printed this vertically on edge (teardrops up @ the pin heads).

I printed these all in PLA+ on my QIDI Plus 4. I believe I used 4-5 perimeters on the Cradle and Feet with 15-20% infill, and the Square would be fine with 3 perimeters and 8-15% infill.

If you have any issues or questions, just let me know. If you want the STEP files, I can pull those and upload them as well.

 

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The author marked this model as their own original creation.

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