Before installing the fence, I needed to rout the t-slots for the hold downs. I did this by just clamping a straight piece of hardwood to the sled to use as a fence for the router.
Here’s a picture with all of the hold down t-slots done
At this point I went ahead and pushed the sled onto the saw blade to have a guide for where the saw will cut.
Then I used the pieces of the fence to set my table saw fence and blade height, to cut out the notches of my stop blocks. Sorry I don’t have pictures of this part. But you really just cut out a notch so the stop blocks will ride on the fence properly.
With that done, I laid the fence out where it was going to go on the sled. Since my sled corners are dead on at 90, I initially used my large carpenters square to place the 2 pieces of the fence at a 45 degree angle to the sides (which geometry class tells us also puts them at 45 degrees to the top edge of the sled).
I then traced pencil lines, removed the fence and put down glue.
Then placed the fence where it needed to go. First by using the carpenter square to get each piece at 45 degrees to the sides
At this point I also made sure the fence point was as close to the center of the saw kerf as I could get it.
Then, I used the largest precision square I have to ensure that the 2 fence pieces were dead on.
I continued going back a forth checking each piece vs. its respective side with the carpenters square, making sure the fence point was at the center of the saw kerf and using the percision square to ensure the fence was right at 90 degrees. I adjusted each fence piece as necessary and stopped when I went through that series of checks 3 times w/o adjusting anything.
Finally, I placed a piece of plywood on top and then a large piece of concrete on top of that since I couldn’t see a great way of clamping this down w/o messing everything up.
Once the concrete was in place I then proceeded to re-check all of the above to make sure nothing had shifted. Everything checked out w/o needing any adjustments, so there it sits to dry overnight.
I think I’ll probably put some screws through the underside of the sled into the fence to make sure it can’t move at all.
Then I’ll make my hold downs and use the sled to cut a frame to put around the maple.