Jumping on the super sled bandwagon

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Project by toddbeaulieu posted 04-11-2011 08:35 PM 4096 views 15 times favorited 18 comments Add to Favorites Watch

I’m so glad to have found this forum and I love looking through the projects.

I’m just starting out, so I’m pretty stinky at most of the basic skills, but I’m slowly moving forward.

I finally got 240v out in the barn and was able to fire up the cabinet saw, which had been sitting around for a full year, serving as a work bench!

I saw the sled projects recently posted and got motivated. I figured it would be a good project to start off with, because it’s basic and also useful for other projects. I decided to go with formal track, instead of slots in the base because they looked cool and fun to implement.

My first base came out so crappy that I couldn’t bear to look at it. In addition to my many screwups (absolutely butchered it with the router, trying to make the mitre slots), the plywood didn’t sit perfectly flat. Something I hadn’t noticed until the very end. You can’t help but see the burned wood on the mitre arm mounted to the sled. My neighbor tells me that’s probably my fence pinching the work piece. Gotta look at that.

So, back to the stores to spend even more money. This was not a cheap sled! I picked up a dado set …. WOW! So much nicer!

This time around I made thee base from 1/2” MDF, sandwiched between thin sheets of plywood. My theory is that the MDF will be much flatter, but would be prone to damage if not protected by the ply. This was my first experience gluing plywood. Wow do you have to work fast!

I dadoed the slots for the top tracks. Had just enough wood left to sink 1/2” screws to hold in the tracks. I also dadoed the rails into the bottom, but just a tiny bit to keep them in place … and so I could use my new dado set, bringing the cost/cut down a little.

I made the fence from two pieces of fingerjointed stock that I had kicking around. Got to play with the jointer and planer with that. I rabitted one of the fence halves, mounted the kreg track in and then sandwiched it in with the second half. While ripping it to the exact height I needed for the stop block, I hit one of the screw heads with my brrand new Forest blade. Later, I also ran it through the kreg rail … remember I said it was dadoed down into the fence? I’m such a hack. :(

I’m really not sure how useful this sled will prove to be, as I’m so new to this. It seems to me that I’ll end up using the mitre saw for cross cuts once I get it mounted in a nice table with another kreg measurement track on it.

18 comments so far

View Bertha's profile


13521 posts in 2657 days

#1 posted 04-11-2011 08:44 PM

That’s one nice looking sled! You’ll find great use out of it and I can only imagine what it was like to hear that cabinet saw roar to life in the barn. Don’t beat yourself up about the mis-steps. Early on, I bought a new PC dovetail jig and set to work. I wasn’t paying attention & routed straight through the side of the template, the template fell & I ripped a dado into the base. Ruined everything. All part of learning :)

-- My dad and I built a 65 chev pick up.I killed trannys in that thing for some reason-Hog

View CharlieM1958's profile


16274 posts in 4182 days

#2 posted 04-11-2011 08:53 PM

Looks fantastic! Now I’ve got sled envy.

-- Charlie M. "Woodworking - patience = firewood"

View jerrells's profile


918 posts in 2849 days

#3 posted 04-11-2011 09:32 PM

Looks goof, welcome to LJ, look forward to your projects.

-- Just learning the craft my Lord and Savior Jesus Christ practiced.

View Routerisstillmyname's profile


763 posts in 3473 days

#4 posted 04-11-2011 10:45 PM

Awesome, but how much you lose on saw blade that looks kind of thick.

-- Router è ancora il mio nome.

View toddbeaulieu's profile


814 posts in 2968 days

#5 posted 04-11-2011 11:21 PM

You don’t lose anything to the blade. You mount the tape at the very end, with a carefully measured block of wood up against the blade. There is also play in the dial so you can adjust it if you change the blade. Simply loosen the screw and bump the indicator.

View toddbeaulieu's profile


814 posts in 2968 days

#6 posted 04-11-2011 11:35 PM

Oh, you meant height, didn’t you? Oh, well … I really don’t know if that will be a problem. Honestly, the track intrudes as mentioned, so height is affected there, as well.

Time will tell!

View Routerisstillmyname's profile


763 posts in 3473 days

#7 posted 04-11-2011 11:37 PM

Hummmmmm, All sleds make you lose from saw blade height of cut due to thickness of the sled.
I was just curious cause I see you have glued ply to ½ inch MDF. no matter. still an Awesome and capable sled.
Table saw without a sled is like …...:-)

-- Router è ancora il mio nome.

View Howie's profile


2656 posts in 2887 days

#8 posted 04-11-2011 11:41 PM

Looks like you definitely dropped some bucks making this. You will find you will use it more than the miter saw(since I built mine, the MS collects dust). By building it this way you will be using it for a lot of years to come. Good job,well done.

-- Life is good.

View toddbeaulieu's profile


814 posts in 2968 days

#9 posted 04-11-2011 11:45 PM

Well, if I find that I need more blade height, I can just buy a 12” tablesaw, right? ;)

View Jim Jakosh's profile

Jim Jakosh

20283 posts in 3070 days

#10 posted 04-12-2011 02:00 AM

Nice sled. You’ll love using it!
Thanks for sharing!!

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Michael J's profile

Michael J

103 posts in 3172 days

#11 posted 04-12-2011 02:06 AM

That’s a super looking sled! LOL Nice work!

-- Mike Minneapolis, MN

View bigike's profile


4050 posts in 3253 days

#12 posted 04-12-2011 02:26 AM

great looken sled I like how you incorporated the kreg stop in there don’t know if you thought about it but the flip stop I think will make a better choice maybe two of them but it’s your sled.

-- Ike, Big Daddies Woodshop,

View toddbeaulieu's profile


814 posts in 2968 days

#13 posted 04-12-2011 02:34 AM

I actually have the flip stop. I bought the kit. I’ll see what seems to work. I want to build a kick butt mitre station, but I have a lot of prep work to the barn infracture first, before I can board up the wall and start building onto it.

I really like those small red woodpecker flip stops on the mitre jigs. Seems like a waste for something I think I’ll use rarely. Oh, and the incra clamp downs are much nicer than I thought. They’re bigger than they looked online.

View hardhead's profile


59 posts in 2617 days

#14 posted 04-12-2011 03:24 AM

Not sure if you run the blade all the way through that base or not…U may want to consider adding a cover on the back side to keep ur fingers away from the blade..if ur anything like i am u may forget to stop and have a severe problem. Just a thought…

-- HardHead.

View toddbeaulieu's profile


814 posts in 2968 days

#15 posted 04-12-2011 03:26 AM

Great idea. Thank you.

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