Bandsaw Sled Design Flaw

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Forum topic by TZH posted 12-16-2009 06:50 AM 1471 views 0 times favorited 3 replies Add to Favorites Watch
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552 posts in 3104 days

12-16-2009 06:50 AM

Don’t know how many of you saw, or remember, the bandsaw sled I posted awhile ago as a workshop jig, but I got a ton of positive feedback on it, and this post is to let you all know there is definitely a design flaw in it that I’m hoping I might be able to get some help on. The sled is a regular 4’x8’ 3/4” sheet of plywood. I found that for just about anything really small, the sled works better even than I expected. It’s when I use if for larger logs that are placed lengthwise that the problem presents itself. The logs are so heavy that they actually bow the sheet of plywood down which pretty much prevents the sled from travelling across the full length of the bed. I’m thinking maybe a roller support underneath might take care of the problem, but thought I’d put it out there to see if anyone else has any ideas. Thanks in advance.

-- Where The Spirit In Wood Lives On

3 replies so far

View DaleM's profile


958 posts in 3348 days

#1 posted 12-16-2009 03:44 PM

Since I’m planning on making something like this, I’ll help you think on it, but I doubt I’ll come up with anything better than you already did. Here are my thoughts although they aren’t very helpful. Since the plywood has to be cut almost full length where the sawblade goes through and you can’t get around that, I think your idea of rollers is the way to go. I was thinking maybe attaching an angle iron on the bottom side of the sled, one along either side of the cut, but it still might sag and you still might need something for it to ride on so the angle iron won’t damage your cast-iron top. With that, you would have to raise the entire thing too, losing some resaw height. Of course adding more wood to the 3/4 plywood would help, maybe some hardwood on the bottom instead of the angle iron, but then it gets heavier, and will probably still sag some, and you lose some resaw height once again. I’m still thinking.

-- Dale Manning, Carthage, NY

View TZH's profile


552 posts in 3104 days

#2 posted 12-16-2009 05:13 PM

DaleM: thanks for your insight. I think I’m just going to need to reconcile myself to losing some resaw height and add something to the plywood to stabilize it. I agree the angle iron isn’t the answer, but I originally started with a raised panel door that didn’t sag at all. I don’t think a solid core door would work too well because of their weight (besides, I don’t have one readily available in my inventory – otherwise, I might try one of those). I’ll take some measurements today and see if that door will work, but instead of putting it on the bottom of the sled, I think I’ll put it on the top to the right of the blade and screw it to the plywood from the bottom up. I’ll let you know how this works.

-- Where The Spirit In Wood Lives On

View RetiredCoastie's profile


999 posts in 3147 days

#3 posted 12-16-2009 05:56 PM

I would think rollers to support the sled would help out. A roller stand on the in-feed and one at the out-feed side would help straighten the sled before it reaches the band saw table. Also instead of angle iron what about square tubing. It would flex less than angle. How much of a bow is there?

-- Proud Supporter of Homes For Our Troops

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