To make a table saw sled, measure and cut the base, cut and attach the runners, cut and attach the fences, make the first cut to create a reference line, attach the front fence, and add finishing touches. A table saw sled ensures precise and safe crosscuts for various woodworking projects, improving the accuracy and efficiency of your work.
A table saw sled is a valuable addition to your woodworking arsenal, providing precise and repeatable crosscuts while ensuring safety and ease of use. In this guide, we will walk you through the steps to create a simple yet effective table saw sled.
Materials and Tools
- Plywood or MDF (for the base)
- Hardwood or plywood (for the front and back fences)
- Hardwood (for the runners)
- Wood screws or glue
- Table saw
- Wood glue
- Sandpaper
- Square or straight edge
- Drill and drill bits
- Clamps
Step 1: Measure and Cut the Base
Measure the dimensions of your table saw’s miter slots and the distance between the blade and the edge of the table. Based on these measurements, cut a piece of plywood or MDF to the desired size for the sled base. A common size is 24″ wide by 30″ long, but adjust according to your specific needs and table saw size.
Step 2: Cut the Runners
Using hardwood, cut two runners that fit snugly into the miter slots of your table saw. The runners should be slightly shorter than the length of your sled base and should slide smoothly in the slots without any side-to-side play.
Step 3: Attach the Runners
Place the sled base on the table saw and align it with the blade. Apply wood glue to the runners and position them in the miter slots. Place the sled base on top of the runners, ensuring they are flush with the bottom of the sled base. Clamp the base to the table saw to hold the runners in place while the glue dries. Alternatively, you can screw the runners to the base from the bottom, ensuring the screws are countersunk and do not protrude.
Step 4: Cut and Attach the Fences
Cut two pieces of hardwood or plywood for the front and back fences. The front fence should be taller for added support, while the back fence can be shorter. A typical size is 4″ tall for the front fence and 2″ tall for the back fence, but adjust according to your preference. Make sure both fences are straight and square.
Attach the back fence to the sled base using wood screws or glue, ensuring it is square to the edge of the sled base. Do not attach the front fence yet.
Step 5: Make the First Cut
With the back fence attached, make a cut through the sled base by pushing the sled through the table saw. Stop the cut just before reaching the front edge of the sled base. This cut will serve as a reference line for attaching the front fence.
Step 6: Attach the Front Fence
Using a square or straight edge, align the front fence with the reference cut line made in the previous step. Clamp the front fence in place, then attach it to the sled base using wood screws or glue. Double-check that the front fence is square to the reference cut before the glue dries or before tightening the screws.
Step 7: Finishing Touches
Sand any rough edges and apply a finish, such as paste wax, to the sled base and runners to reduce friction. Optionally, you can add a safety stop block to the front fence, a blade guard, or a T-track for adjustable stop blocks to enhance the sled’s functionality.
Now you have a table saw sled that will provide precise and safe crosscuts for your woodworking projects. Remember to practice proper table saw safety when using your new sled.
| Component | Function |
|---|---|
| Base | Provides a stable and smooth surface for the workpiece to slide on during the cutting process. |
| Runners | Glide in the table saw’s miter slots, ensuring smooth and accurate movement of the sled. |
| Fences | Support and guide the workpiece during the cut, maintaining a square and precise alignment. |
| Stop block | Allows for setting a specific length for repeatable and accurate crosscuts. |
| Blade guard | Provides an additional safety feature to protect the user from accidental contact with the blade. |
Table: Table Saw Sled Components and Their Functions
Using Different Types of Table Saw Sleds
While the simple sled described in this guide is perfect for basic crosscuts, there are other specialized sleds for different purposes:
- Miter sled: Designed to make accurate miter cuts at various angles, this sled features an adjustable fence that can be set to the desired angle.
- Panel sled: Larger than a standard sled, a panel sled accommodates cutting larger sheets of material, such as plywood or MDF panels.
- Box joint sled: Specifically designed for cutting box joints, this sled has an adjustable fence and stop system to create precise, repeatable box joint cuts.
Safety Tips
- Always use safety gear, such as safety glasses, hearing protection, and a dust mask when operating a table saw.
- Ensure the table saw is turned off and unplugged when making adjustments, changing blades, or performing maintenance.
- Keep your hands clear of the blade and use push sticks, push blocks, or hold-downs when necessary to maintain a safe distance.
- Be aware of the potential for kickback and use safety features like a splitter or anti-kickback pawls to reduce the risk.
Maintenance
Regularly maintaining your table saw sled will ensure optimal performance and a longer lifespan:
- Inspect the runners for wear and tear and replace them if necessary.
- Check the fences for squareness and adjust as needed.
- Clean and lubricate the runners and miter slots to ensure smooth operation.
- Inspect the base and fences for damage or warping and repair or replace as needed.
By taking these additional factors into account, readers will be better equipped to use and maintain their table saw sled safely and effectively.
