Choice of Coping Sled
Allen, the sled I was looking at is, in fact, the Infinity. I was thrown off a bit because their's rides along the fence instead of being guided by a miter slot. I'm over-tasked right now putting an entire new shop into order so I'll buy instead of build. And with the Infinity, I save the trouble of having to install a miter slot into my router table.
The router I intend to use is a Milwaukee 5616 (2 1/2 hp). I learned to make doors using a shaper. It had 7hp. While checking up on this stuff I telephoned Pat Warner (of router book fame). He said he wouldn't make a coping cut using a router. It beats the hell out of the machine. But with very small, incremental cuts, it is ok, and lots of people do it, according to Pat.
Tony, it is easiest to understand a Cope if you look at a frame and panel door. The sides (vertical) are the Stiles, and these are given a Stick edge with a router or shaper. Then, to join the Rails, you make a Cope on the 2 ends. The Cope is like a "hand in glove" fit to the profile of the stick. It really serves as a stub tenon joint to the Stick or Stile. Very pretty to look at. Not quite as strong as a real Mortise & Tenon, but fine for doors in cabinets.
The challenge is cutting across that end grain on the Cope. It is hard on the machinery, the cutter. And somewhat dangerous as well.
Gary