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Super duper table saw sled

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Project by MW_Woodworking posted 11-11-2013 01:10 AM 3039 views 26 times favorited 16 comments Add to Favorites Watch

Here is my version of a table saw sled, measuring 2ft by 3ft with a 4ft fence. My inspiration came from various videos I’ve seen on the internet, but I want to give credit to Eaglelake Woodworking for the biggest inspiration.

The base is 3/4” birch plywood and the rest is oak. For the guide I used an aluminum channel and routed a dado into the underside, drilled a few holes in the aluminum and attached with screws. Since I got my table saw at the big blue store, tried out a couple of channels on the display model until I found one that fit in the slot but had the least play. When I got home, I measured the slop with my table saw and it was less than 2 thousands of an inch, really good for me. I routed slots in the face and top of the main fence for stops, etc. I routed out four parallel channels to attach aux fences, jigs, and accessories and routed an arc for a protractor attachment. I have made two miter attachments and a stop for the main fence and a stop for the miter fence so far. I will make the other jigs as I need them. I printed out a protractor to attach but I haven’t decided whether to glue on the paper or etch in the angles, but I will make that decision when I need to use it. I drilled a hole in the front for a pencil, im always trying to remember where I put one down. Finally I waxed the bottom.

I’ve had the sled done for a while, but finally got some plexiglass and added the guard today. It cuts well, I’ve had the chance to use it a dozen times or so and am pleased with it so far.

Hope you like it. Any comments or suggestions are welcome. Thanks!

-- Matt ~ "Show us a man who never makes a mistake and we will show a man who never makes anything.” - Herman Lincoln Wayland (1830-1898), author





16 comments so far

View aussiedave's profile

aussiedave

3014 posts in 474 days


#1 posted 11-11-2013 01:19 AM

A very nice crosscut mitre sled Matt….looks like an excellent build, well done.

-- Dave.......Keep calm and make more sawdust....

View luv2learn's profile

luv2learn

1693 posts in 952 days


#2 posted 11-11-2013 02:40 AM

Great build Matt. I have the super sled by Eaglelake bookmarked and on my build list.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View mIps's profile

mIps

174 posts in 704 days


#3 posted 11-11-2013 03:22 AM

It’s a good looking sled with lots of features, however I would worry about angle repeatability (returning to 45 for example). How does this work?

-- Be honest, honorable, kind, work hard, and generally be awesome.

View MW_Woodworking's profile

MW_Woodworking

22 posts in 340 days


#4 posted 11-11-2013 04:19 AM

Some drill a hole for stops (on the back side of the miter fence) at 45 degrees and whatever angles they want. I plan to just use a carpenter square to set one 45 from the blade and then a framing square to set the opposite side. Or some other angle measuring device. I might add stops at some point but just plan to measure the angles for now.

-- Matt ~ "Show us a man who never makes a mistake and we will show a man who never makes anything.” - Herman Lincoln Wayland (1830-1898), author

View Rick's profile

Rick

6454 posts in 1682 days


#5 posted 11-11-2013 06:23 AM

Very Nice Work Indeed! Thanks For Sharing.

Rick

-- COMMON SENSE Is Like Deodorant. The People Who need It Most, Never Use It.

View a1Jim's profile

a1Jim

112061 posts in 2227 days


#6 posted 11-11-2013 06:44 AM

cool looking sled

-- http://artisticwoodstudio.com Custom furniture

View Tooch's profile

Tooch

614 posts in 526 days


#7 posted 11-11-2013 10:46 AM

very nice! almost looks too good to use

-- "Well, the world needs ditch-diggers too..." - Judge Smails

View Dinger's profile

Dinger

126 posts in 912 days


#8 posted 11-11-2013 02:58 PM

Love the protractor idea. How do you register the mitre fence to 45 degrees repeatably? It looks like you have two hold down knobs and it could be different. Just curious. Great looking project. Waxing the bottoms makes a huge difference doesn’t? :) I used a couple coats of danish oil first and then wax. What a difference!

-- "Begin every endeaver with the end ever in mind."

View ward63's profile

ward63

318 posts in 1737 days


#9 posted 11-11-2013 03:08 PM

Excellent work! Really like the plexiglass guard.

View eddie's profile

eddie

7316 posts in 1263 days


#10 posted 11-11-2013 03:13 PM

nice sled

-- Jesus Is Alright with me

View BTimmons's profile

BTimmons

2123 posts in 1135 days


#11 posted 11-11-2013 03:44 PM

The pencil hole in the rear fence is a neat idea.

-- Brian Timmons - http://www.BigTWoodworks.com

View MW_Woodworking's profile

MW_Woodworking

22 posts in 340 days


#12 posted 11-11-2013 04:16 PM

Thanks everyone for the praise!

Dinger – I plan to measure the angles I need, at least for now. In the Eaglelake video, stops are added to the sled, which I might do someday. Any suggestions are welcome, I’d love to hear what what others do. As far as the protractor, I will make a pivot point and make a fence that includes a plexiglass window to align with the tick marks, like the Rockler jig:

http://www.rockler.com/portable-cross-cut-sled

-- Matt ~ "Show us a man who never makes a mistake and we will show a man who never makes anything.” - Herman Lincoln Wayland (1830-1898), author

View Roger's profile

Roger

14536 posts in 1454 days


#13 posted 11-12-2013 12:59 AM

Now that’ a sled. Well done, Matt.

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View mrbreezeet1's profile

mrbreezeet1

54 posts in 802 days


#14 posted 11-14-2013 04:07 AM

Does lowes sell the AL channel?
Is it 3/4”?
I am trying to decide to use UHMW plastic, wood, or something else. TSC had some AL 3/4” wide, but it was only about 1/8” thick.

View MW_Woodworking's profile

MW_Woodworking

22 posts in 340 days


#15 posted 11-14-2013 01:04 PM

Mrbreezeet1 – I did buy it at Lowes, but I used a 3/4×3/4 aluminum tube and routed a 3/4×3/8+ dado in the 3/4 plywood. I couldn’t find any metal that was 3/8×3/4 at several stores.

-- Matt ~ "Show us a man who never makes a mistake and we will show a man who never makes anything.” - Herman Lincoln Wayland (1830-1898), author

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