TOTsled Dustless Router Sled System Owner’s Manual

Dustless Router Sled System

Owner’s Manualhttps://totsled.com

TOTSLED XL

1. Router cart
2. Cross rails brackets
3. Cross rails
4. Base (parallel) rails
5. Plexiglass router base
6. Handle
7. Rail extensions
8. Rail extension connectors
9. Star knob
10. Locking lever

Parts

Hardware

M5|
---|---
M5 x 20mm Hex bolt| 3
M5 Washer| 3
M5 Nyloc nut| 3
M6|
M6 x 15mm Hex bolt| 12
M6 x 20mm Hex bolt| 24
M6 x 60mm Hex bolt| 4
M6 Washer| 74
M6 Spring washer| 13
M6 Nyloc nut| 32
M6 T-slot nut| 12
M6 Wing nut| 9
M8|
M8 x 15mm Hex bolt (centering bolt)| 1
M8 T-slot nut| 6
Bearings| 16
Wrench 10mm| 1
Allan key 3mm| 1
Allan key 4mm| 1

ROUTER CART

Carriage frame assembly
Items

Do not tighten the top wheels, you will need to adjust them later.

Router Cart
Items

Place the M8 x 15mm centering bolt through the center hole to line up the router cart and carriage frame assembly together.

CROSS RAIL BRACKETS

Carriage assembly
Items

When securing the plex guard, thread both “A” nuts about ¾” down the bolt. Place the plexin guard on the bolt. Thread the “B” nuts on the bolt until they are flush with the end of the bolt, then tighten “A” nuts to secure the plexi guard. DO NOT OVERTIGHTEN!

Cross rail brackets

Items

Place the M8 x 15mm centering bolt through the center hole to line up the cross rail bracket and carriage frame assembly together.

SET UP A & B

Set up A

CROSS RAILS

Items

Set up B – 2m (80”) length
M6 x 15mm Hex bolt| 12
M6 Spring Washer| 12
M6 T-slot nut| 12

1. For maximum system width line up the outside edge of the cross rail brackets with the end of your rails.
2. Make sure that the bracket assembly and rails are perpendicular (100% squared off) to each other before you tighten them.

• You can choose between the 1.5m (60”) and 2m (80”) long rails to adjust the width of your system.

SETTING THE WIDTH OF YOUR CROSS RAIL BRACKETS

If you can NOT use maximum system width (your work bench is not wide enough) make sure the distance between cross rail brackets is set as shown below. (2” or 50mm longer on each side from outside diameter of the base rails).

BASE RAILS

Items

1. To get the most out of your Tots led system you need to mount it to a sturdy flat surface. A proper size work bench works great.
2. Break off tabs on the back of your 90° brackets.(tip: use pliers to knock-it off)
3. Lay out your base rails to desired width, secure them to your work surface and make sure they are parallel. To secure the bracket to your work surface use wood screws (not incl.) with washers.
4. You can also use your cross rails to set your base rails. Set both of your base rails on your work surface. Secure the first base rail and then mount your cross rails on top. Now adjust the second base rail so the cross rails are set perfectly on the base rails and secure it in position.

EXTENSIONS

Items

Set up B – 1.5m (60”) length
Linear connector (incl. set screws)| 6
90° bracket (incl. hardware)| 6

When tightening the linear connectors, start with the one placed in the top slot. This will help to ensure proper alignment of the rails and will result in smoother transition.

ROUTER NESTING

Flange assembly
Items

Do not overtighten or you can crack your Plexiglass base!

Router nesting
Items

1. Use any type of router bit with the point end to center your router on the Plexiglass router base.

2. Attach the vacuum adaptor and hose.

3. Position the router in a way that you can operate it without interference.

4. Once you reach the desired position, mark the router base plate location on the
   Plexiglass router base with marker.

5. Remove the router base plate from your router and use it as template to mark holes on the Plexiglass base in your marked position.

6. Drill holes into the Plexiglass base. Use drill press with required size of bit to fit your base plate screws.

7. Attach your base plate back to your router.

8. Remove the “knockout” –middle piece – (push it off) on the Plexiglass base and affix your router with flat head bolts and washers.

9. Place the Plexiglass router base back to your router cart and tighten it down using M6 Wing nuts.

DO NOT USE counter sink head bolts to attach router base plate to Plexiglass router base, you risk cracking the base!

MISCELLANEOUS

Handle
Items

Do not tighten the handle joint all the way.
This will ensure the handle rotates.
Brushes
Items

Your Tots led contains 3 sets of sealing brushes to provide proper seal on materials of various thicknesses.

1. Flip the router cart upside down with the dust collection port pointing towards you.
2. Remove both front locking pins. Make sure that the spring is seated against the rear locking pins.
3. Slide the long side brush (1) in place. Push the brush against the spring and put the locking pin back in place.
4. Slide both short brushes (2 & 3) in place.
5. Slide the other long brush (4) in place to lock the short brushes (2 & 3) in place.
6. Push the brush against the spring and put the locking pin back in place.

Setting your stops
Items

Secure the star knob with M8 T-slot nut in desired position on top of the profile to function as a travel stop for both router cart and cross rails assembly. Always double check your stops before using your router sled.

IMPORTANT NOTE:
IF YOU HAVE YOUR BASE RAILS SET FOR WIDTH THAT IS SMALLER THAN LENGTH OF YOUR CROSS RAILS, ALWAYS MAKE SURE THAT YOUR STOPS ARE SET PROPERLY AND YOUR ROUTER BIT CANNOT HIT THE BASE RAILS.

Locking lever vs. locking jig
Items

https://www.youtube.com/watch?v=IOgGibZlXuQ
Scan to watch the “locking jig” video

We strongly recommend using the LOCKING JIG (not included with the kit) to replace locking levers. Locking jig has added efficiency and speeds up your process when working on bigger slabs. Locking jig is attached to your cross rails.

SELF SUPPORTING FRAME (SSF) – OPTIONAL

Items

1. Lay out your SSF rails on a flat surface following the recommended spacing.
2. Using the 90° brackets attach your Base rails to top of your SSF rails.

Dimension X:
Set up A – 610-660mm (24-26”)
Set up B – 530-585mm (21-23”)
Install your SSF rails standing tall instead of laying them flat. This gives you higher load bearing capacity. SSF is not included with the kit.

WARRANTY

WARNING
Always wear appropriate PPE-Personal Protective Equipment (eye, skin and respiratory).
Dust may contain hazardous substances that can cause serious injury from repeated exposure. Provide appropriate local exhaust (or dust capture) while using this product.
Minimize dust exposure to bystanders. While using a power tool, follow the manufacturer’s safety instructions.

Warranty and Limitation of Liability

Tots led warrants that each Tots led part meets the applicable product specification at the time we ship the product. Tots led makes no other express or implied warranties or conditions, including any implied warranty or condition of merchantability or fitness for a particular purpose. If the Tots led product does not conform to this warranty, the sole and exclusive remedy is, at Tots led option, replacement of the Tots led product or refund of the purchase price. TOT sled will not be liable for any loss or damage arising from the Tots led product, whether direct, indirect, special, incidental or consequential, regardless of the legal theory asserted.

References

• Router Sled - TOTsled | Dustless router sled system

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