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Fully Adjustale Table Saw Sled for Cutting Bowl Segments

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Project by ruizd posted 314 days ago 4183 views 34 times favorited 20 comments Add to Favorites Watch

This is my new fully adjustable table saw sled for cutting segments for making segmented bowls. The sled can be adjusted to almost any angle between 90 and 45 degrees. For the pictures, I have it adjusted for cutting 15 degree angles on both sides of the work piece for a total of 12 segment pieces to make one ring.

The sled is made from a 2’ x 2’ x ¾” Apple plywood. I chose ¾” over ½” this time because I wanted to make sure the sled remains flat and stable. I had a simple version of this sled before that was ½” Baltic birch and over time it slightly bowed. To keep the sled from advancing too far over the blade and cutting a kerf completely all the way through the sled, I use a stop block in the miter slot of my out feed table. The runners are made from UHMW material and the sled glides quite nicely on the table saw top. The adjustable fence and smaller stop are made from Oak hardwood. The sled’s front fence is a made from a scrap piece of ash hardwood I had left over from another project. I used 5/16” T-bolts and the slots cut in the sled are 3/8” to allow a 1/16” play and for fine angle adjustments and 3 each 5/16” T-knobs.

I use a digital protractor to make the fine angle adjustments. This sled is not my original design. I took the design from a segmented wood turning book and instead of using t-tracks for the fence hold downs I decided to cut slots for t-bolts instead for strength.

I cut walnut and oak segments (pictured) then put them all together for an almost perfect ring (final sanding of each half will fix being off by about 0.10 of a degree). Since the sled is fully adjustable you can also use it for 90 and 45 (and anything in between) cuts. I still need to figure out some sort of hold down method for safely securing the work piece when it gets very short.

-- Dan - A good day is when you are done in the woodshop with all your fingers still attached!





20 comments so far

View mcoyfrog's profile

mcoyfrog

2477 posts in 2096 days


#1 posted 314 days ago

Nice job!!

-- Wood and Glass they kick (well you know) Have a great day - Dug

View DIYaholic's profile (online now)

DIYaholic

11246 posts in 1177 days


#2 posted 314 days ago

A nicely executed sled!

I hope to make one of a similar design for my TS. Although, for increased safety, I’ll try to incorporate a block to conceal the blade as the cut is finished.

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View HorizontalMike's profile

HorizontalMike

6701 posts in 1416 days


#3 posted 314 days ago

DIY has a good point. A rear fence will lend safety PLUS it will hold the sled together if/when a brain fart causes you to slip and push the sled too far, separating the sled bed. Other than that, great job! The adjustable fences come in really handy.

-- HorizontalMike -- "Woodpeckers understand..."

View rance's profile

rance

4106 posts in 1662 days


#4 posted 314 days ago

Nice design, and nicely executed. I’m curious why you only have 1 bolt slot on the right fence.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View ruizd's profile

ruizd

23 posts in 551 days


#5 posted 314 days ago

The right side acts mainly as a stop for the cut work piece so only one slot was needed. As long as I tighten it snug it does not move without using force. I did consider adding a second slot for the right but it would have been very close to the right runner so I left it at one.

-- Dan - A good day is when you are done in the woodshop with all your fingers still attached!

View ruizd's profile

ruizd

23 posts in 551 days


#6 posted 314 days ago

Thanks all for the positive feedback. I use a stop block on my out feed table so the sled will not cut all the way through. That’s not to say I shouldn’t incorporate some sort of rear fence or thick block for safety. That is possibly one of two pending additions. The other is some sort of clamping system to hold down the work piece when it’s < 2” – 3”. The idea I have in mind is to use a lever clamp on a small 3/4” thick block with enough room to cut a 5/16” hole for a T-bolt and T-knob to use in the left side slot closest to the blade for securing short pieces.

-- Dan - A good day is when you are done in the woodshop with all your fingers still attached!

View Sodabowski's profile

Sodabowski

1968 posts in 1335 days


#7 posted 314 days ago

For the hold down you can find cheap small toggle clamps on ebay, you would just need to widen your adjustable guides to accomodate for these. Pretty good design, I keep this aside for future reference, thanks for sharing ;)

-- Holy scrap Barkman!

View Francois Vigneron's profile

Francois Vigneron

248 posts in 821 days


#8 posted 314 days ago

Nice sled. This hold down might work for you : http://www.rockler.com/product.cfm?page=22010

The tip has non-slip coating and it might be long enough (5-1/2’‘L x 1-1/8’‘W) that you can just use the T-slots closest to the blade without any modification to the sled. Be safe & keep up the nice work.

-- Francois Vigneron, Gif-sur-Yvette, France & Altadena, CA

View Paul Lajoie's profile

Paul Lajoie

111 posts in 1606 days


#9 posted 313 days ago

Nice work. I don’t do segmented yet, but hope to try soon. This will be going on my to do list.

Paul

View woodsmithshop's profile

woodsmithshop

1083 posts in 2047 days


#10 posted 313 days ago

look at this blog for an idea on clamping small pieces

http://lumberjocks.com/dustbunny/blog/11197

-- Smitty!!!

View a1Jim's profile

a1Jim

109347 posts in 2079 days


#11 posted 313 days ago

Nice work

-- http://artisticwoodstudio.com Custom furniture

View Jim Jakosh's profile

Jim Jakosh

10250 posts in 1607 days


#12 posted 313 days ago

Very nice, Dan.Ii love that digital protractor for getting the angles Right On!!

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!!

View HorizontalMike's profile

HorizontalMike

6701 posts in 1416 days


#13 posted 313 days ago

Harbor Freight also has cheap, good clamps as well.

http://www.harborfreight.com/catalogsearch/result?q=toggle+clamps

-- HorizontalMike -- "Woodpeckers understand..."

View BBF's profile

BBF

141 posts in 341 days


#14 posted 313 days ago

I just love comming to LJ and stealing ideas. I mean borrowing them. I’ll give them back when I’m done or maybe I’ll just pass them on to someone else.

-- I've never been disappointed buying quality but I have been disappointed buying good enough.

View BBF's profile

BBF

141 posts in 341 days


#15 posted 313 days ago

Don’t you love it when you are faster than your computer and it posts things twice.

-- I've never been disappointed buying quality but I have been disappointed buying good enough.

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