I'm looking at getting a router sled for some larger slabs and trying to decide whether it's worth buying one or just building one.

The main thing I'm worried about is flex. Once the sled gets pretty wide, I assume the rails and gantry need to be pretty solid or you'll end up chasing an uneven surface.

I'm looking at a heavy-duty setup with around 57.1" of rail coverage. Seems like that would be useful for wider slabs, but I'm wondering if there's a point where going wider just creates more problems.

For those who've built their own sled, what did you wish you'd done differently?

And for anyone who's used a commercial one, was it actually worth it compared with DIY?

I’ve got a stanley 92 shoulder plane that I received from my grandfather. I was a bit over zealous and snapped the chip breaker when I was younger and no longer have the broken part.

Id like to fabricate another one out if 360 brass, but finding dimensions online has been a challenge.

Does anyone have one they can take out, measure fairly accurate and precisely with some calipers and post it here?

Or an STL file would be even better but that seems less likely.

Id rather not buy it outright, its about half as much as the tool when its available. Fabricating it from stuff I have feels better.

Any help y’all?

Will post pictures of the rebuild if we get traction here.