Super Duper Sled V2

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Project by Lumberpunk posted 03-08-2016 09:38 PM 3505 views 32 times favorited 7 comments Add to Favorites Watch

I made my Super Duper Sled ( almost 2 years ago and although it has served me well it was starting to get a bit worn out… time for a new one! This one has a couple of improvements over the last one. 3/4” MDF base with a laminated birch fence.

Improvement #1 (Pic #2 & 3) Removable zero clearance inserts in base. I milled a quarter inch deep dado 1 3/4 inches wide in the surface of the sled so I could make removable inserts (1/4” baltic) for when they get worn out or when I want to use a dado stack or do a bevel with the sled. This works really well, the ZCI is held in place by 6×5/8” #8 screws right now but I am planning mount some 3/16” nuts in the bottom of the sled and use machine screws as the woodscrews won’t last long in the MDF. The inserts slide under the front and rear fences perfectly (pic #3).

Improvement #2 (Pic #4) Subfence. I also made a removable subfence out of 1/4” Baltic Birch. It mounts in a T-Track milled into the fence face with 1/4” machine screws and can be trimmed and adjusted as it wears out or changed out for dados.

Improvement #3 (Pic #5) Micro adjustable stop blocks. I drilled out my stop blocks for a #8 woodscrew which make for a surprisingly good micro adjust. The rulers in the top of the fence (Pic #6) can also slide for calibration much like an Incra miter gauge.

Squared with the 5 cut method but it was within .002” over 4’ straight off so I didn’t mess with it.

One thing I would have done different is cutting a sliding dovetail instead of the dado for the base inserts but what I have works just fine.

Thanks for looking.

-- If someone tells you you have enough tools and don't need any more, stop talking to them, you don't need that kind of negativity in your life.

7 comments so far

View kiefer's profile


4873 posts in 2086 days

#1 posted 03-08-2016 10:34 PM

Looks good and big with some interesting features .
I like the ZCI as it allows you to cut on a bevel which I like about my sled .
Great to see those Robertson screws and a gap under the sub fence for sawdust .


-- Kiefer

View Lou's profile


66 posts in 609 days

#2 posted 03-09-2016 12:42 AM

Beautiful!! On my favorites!!

-- What to make next. Hmmm.

View oldrivers's profile


710 posts in 985 days

#3 posted 03-09-2016 12:58 AM

Very nice good work ,thanks for sharing.

-- Soli Deo gloria!

View SuperCubber's profile


832 posts in 1703 days

#4 posted 03-09-2016 12:58 AM

Great sled. One of the best executions I’ve seen as far as sleds go. All very usable add-ons without going overboard.

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

View helluvawreck's profile


22669 posts in 2285 days

#5 posted 03-09-2016 03:34 PM

This is a fine sled you have made and a great addition to your shop.

helluvawreck aka Charles

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View ravensrock's profile


328 posts in 1061 days

#6 posted 03-09-2016 05:43 PM

Great looking and functional sled! Should serve you another 2 years!

-- Dave, York, PA, WildSide Woodworking

View GrandpaLen's profile


1643 posts in 1691 days

#7 posted 03-09-2016 07:51 PM

Upgrades evolving from past performance, is always a Winner.

Thanks for sharing.

Work Safely and have Fun. Len

-- Mother Nature should be proud of what you've done with her tree. - Len ...just north of a stone's throw from the oHIo, river that is, in So. Indiana.

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