Ski Sidewall Milling Adapter for Router

This 3D-printable adapter is designed to mount onto the Bosch GKF 12V-8 / Dewalt DCW600 trim router, turning it into a dedicated tool for milling ski sidewalls. Inspired by commercial sidewall milling tools (such as the Carrot sidewall machine: https://shop.carrot.ski/professionalskitools/electric-sidewall-machine/), this design offers a cost-effective alternative—providing a complete solution for 1/5 the price.

The holder features a fixed 5° angle, suitable for most common ski tuning needs. Depending on the desired sidewall shape, a specific angle or radius can be manually ground onto a standard 16 mm wood router bit to achieve custom profiles above the edge.

For precise control, the adapter includes an M5 adjustment screw that allows fine incremental depth adjustment. On the opposite side, a simple cylindrical pin acts as a guide—this can be made easily by cutting a piece from a standard wood screw.

Disclaimer
No guarantees are provided regarding safety, accuracy, or performance. Use at your own risk. If the tool is set up incorrectly or used improperly (for example, cutting too deep and milling into the wood core (at 5° more than 1mm of material is removed at the top!), full responsibility lies with the user.

Hardware needed:

• wood screw with a shaft diameter of 3.5mm

• M5-30 Hex Screw

• M5 Nut

• 16mm Router Bit -> needs to be modified

Build Guide, refere to the drawing!

• 3d Print

  • Drill the adjustment hole to 4mm

  • cut a M5 thread

  • sand the angled platform smooth to avoid base damage

• Screw

  • grind of the first mm of thread to a diameter of about 4mm

  • grind the tip a little bit convex so you dont damage your edges

• Guide Pin

  • cut of a piece of shaft of a woodscrew with a diameter of 3.5mm

  • press / glue it in

• Milling Bit

  • buy a normal 16mm router bit (for Wood/Aluminum)

  • grind on the bottom the desired shape, flat/radius (refere to the drawing)

User Guide:

• Try it out with a broken Ski

• Position the tuning vices as far out as possible, if needed clamp the ski down

• Sneek up 1/4 of a turn per pass until the second edge starts to be milled

• Don't mill the first/last 15cm of the ski -> use a panzer file at 30°-45°

• keep both hands on the tool, always apply preassure

• slide the guide pin to the edge and then swivel the tool to the ski so the adjustment screw touches the edge

• push the router slowly in the material, never lift it up!!! always swivel to the side

• never push with the milling direction, always against it! -> mill in the direction of the guide pin

• After milling: sand with finer and finer grids for a perfect surface finish.

If you want a different angle, I can modify the model for you, just message me. I always grind the skis when they are new and dont have any bindings mounted, if there is demand I can modify the model and remove the guard.

EDIT1: I uploaded a second Version without the guard to clear bindings.
EDIT2: Uploaded a second version for the Dewalt DCW600