Now here is something else I didn’t do last time. Properly squaring up the sled.
I start by lining up my nice new fence, and dropping ONE screw only on the far side.
Then I slice a kerf just high enough to pop through the ply, and line up the fence roughly with the square. (This part is NOT how it gets squared… read on!)
Looks square, doesn’t it?
I made a small T adjustment block, and grab about 1/16 inch worth of sliced up index card and paper, and jam it in between the sled fence, and the block.
I flip the sled over, and screw my adjustment block in place.
Then I flip it back, and clamp that monster together.
Note: When you’re trying for something this precise, you have to keep the saw, and the sled clean. You are trying for hundredths of an inch accuracy, so dust like this can throw the whole thing off.
I vacuumed in between each test run.
I begin the 5 cut squaring process. You can read about it here.
After 7 runs, I finally got it accurate. And far more accurate than I ever expected: