Dado Sled and rabbet fence

  • Advertise with us
Project by lumberjoe posted 07-09-2012 08:29 PM 4376 views 9 times favorited 4 comments Add to Favorites Watch

Sorry, but I love making sleds. This is the first dado sled I have made. Comments and suggestions welcomed! This one is quite a bit smaller than the cross cut sled(s) I made. It’s 24” by 24” square. I was always a little hesitant to cut dadoes on the table saw, but I think this makes it a lot safer.

Base – 1/2” plywood 24” by 24”
Runners – Hard Maple
Rear fence – 3/4” plywood x 2 – 24” wide, 3 1/2” tall, 1 1/2” thick
Front Fence – 3/4” plywood – 16” wide, 3 1/2” tall
Incra T track
Woodpeckers T track stop
Kreg track clamp
Red Oak handle and stop block

I borrowed the t-track and t-track stop idea from my other sled. I didn’t get one with a ruler this time though. It is very handy. You can set your measurement with the track stop, then slide the stop block out of the way when making your cut. When you need to cut the next piece, slide the stop block right back. Much cheaper than a swing stop. I also routed some slots for the track clamps to hold the pieces down. There is a blade guard on the back.

I initially cut this with my regular blade. It made it easier to square the fence since I have a straight edge that is exactly as thick as the blade kerf. Once the fence was squared using the 5 cut method, I put the dado on in a 5/8 configuration and cut the slot. I made many test cuts and they are all square. I even cut a “tenon” to be sure all the sides lined up, and they did

The other “accessory” I made is a fence for rabbeting. It’s a 6” tall piece of 3/4” melamine shelf. I got the shelf because it is banded on the edge. That stuff falls apart if you move it around a lot. Securing to the fence on the R4512 was tricky. There are t-tracks in the fence, but the tracks are really low. The bolts would interfere with a pushstick/pushblock. I attached it to a piece of wood and used the t-tracks on top of the fence to secure it. I routed out a slot for the t-track style feather board to slide back and forth. I then raised the dado blade into the melamine so I can cut rabbets.

That Freud SD208 cuts pretty clean:


4 comments so far

View lumberjoe's profile


2899 posts in 2450 days

#1 posted 07-09-2012 08:43 PM

Also, huge thanks to helluvawreck for some tips he posted in my blog when I was making a cross cut sled. Aside from letting glue set, this went really quick.

Another trick I found making my cross cut sled that people may find helpful. I made the back fence out of 2 pieces of plywood glued together so it would be 1 1/2” thick. You can’t run plywood through a jointer (as far as I know). For a 4” tall fence, I cut one of the pieces 4 1/”2 inches, and the other 4”. I am not careful at all when I glue it up.

After the glue has set, I remove the clamps and rip the sides about 1/4” each. The plywood is already perfectly straight, and you only have the one long piece touching the fence. That way I end up with a straight laminated 1.5” thick piece of plywood


View Yupa4242's profile


116 posts in 2802 days

#2 posted 07-10-2012 03:20 AM

Really like the t-track part of this sled for the stop solution :)

-- "If the Universe is Infinite, Then all dreams are real."

View Kevin's profile


561 posts in 2500 days

#3 posted 07-10-2012 02:20 PM

Nice sled, you gave me a few ideas.

-- Measure twice, cut once, then sand a whole bunch

View lumberjoe's profile


2899 posts in 2450 days

#4 posted 07-10-2012 02:22 PM

Thanks Yupa4242. It works really well. I didn’t incorporate a ruler in this one. I find that I like to line up pencil marks to the dado kerf on the sled instead. I also only cut the kerf at 5/8”, so any dadoes wider than that will need multiple passes.

I am actually going to replace the t-track on this one. Kreg makes a combo track with rails on the top and side. That way when I have a piece vertical to cut the shoulders, I can use a track clamp to hold it down


Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics