My table Saw Sled

[Tribalvision]

Since my recent Table saw tune up, I've done some research on helpful table saw jigs. I came across the table saw sled and it looked like a valuable tool for the table saw. It didnt look too difficult to build and it wasnt.

i started off with some strips ripped down to size to fit the guide slots in the saw table.

Next i used a piece of 1/2" MDF as the base. I placed it on the table and just squared it to the edge of the table to get it close. then glued and tacked the guide strips to the base with 3/4" brads. let it dry and this is what it looks like when removed from the table

The next step was to make the front fence. To do this I laminated 2 pieces of 3/4" Oak. the I ran them thru my friends planer and jointer to make sure all sides were true and parallel.

I cut some reliefs on each side for a place to put your hands when feeding the sled.

I used a round over bit and smoothed out the edges and cut a chamfer in the bottom of the base so sawdust didnt build up and effect the work piece cut.

I set the fence on the base and flush fit it to the front and clamped it. I drilled and counter sunk a screw on one side only.

Next, put the sled in the slots and center the sled on the table. turn on the saw and slowly raise the blade so it cuts thru the sled base. Then cut the base toward the front and stop when there is about 2" left to cut and back out of it. Dont cut all the way thru the front of the fence yet.

my blade makes an 1/8" kerf, so I used a couple 1/8" drill bits and set them in the kerf slot. Now I used my square against the drill bits and the fence to square the fence.
I clamped the fence and checked for square on both sides of the blade.

Once I was satisfied with the fence location,I drilled and countersunk 6 screws thru the base and into the fence. recheck square.

I then took a scrap piece of plywood and secured it to the rear of the sled. the rear fence is just there for strength, it doesnt have to be perfectly square. I just flushmounted it with the MDF and attached it with screws.

Almost finished.

now, remove the sled and raise the saw blade to max lift. start the saw and cut thru the whole sled. Be very careful of the blade protruding thru the front. Keep hands and shirts out of the way..
it should look a little like this.

Now for the blade/hand protector.
first i glued/nailed a small pice of plywood right over the previous cut. this will give me something to secure the box to.

I cut a few small pieces out of the plywood i had and just made a small box where the blade protrudes thru the front. glued/nailed it together and glued/nailed it to the mounting block

all finished

Now give it a whirl.
I put some ply on the sled and cut a pass on both the length and the width.

It doesnt get much more square than this..

the sled works great for pattern work. just clamp a block at the set measurement and you can cut exact duplicates over and over.


hope you enjoyed the pics

 

[rlitman]

The first change I'd suggest, is using something clear, like plexi, to cover the box where the blade comes through the front. It lets you actually see the blade, and lets you see if the box is getting full of dust.

The second suggestion (and this one is a little hard to describe in words, but I don't have a picture handy), was something I came up with to prevent pushing the sled too far.
I bent a hook, that was about a foot long out of 1/4" steel rod. It had an eye at one end, and was just bent over into an L at the other end. I then loosely bolted the eye with a lag screw and two washers to the side of that box. When the sled was all the way back, it hung below the table. As you pushed the sled forward, it would start to pick up, until the end would catch on the fence and prevent you from pushing the sled any further.
The odd part of the design, was that the eye was on the side opposite the L (so with the bar facing straight back the L would hook down, and the eye would be above the bar. This way, you could flip the whole thing up and over the front rail, and it would hang over the sled for storage.

 

[Tribalvision]

thanks for the advice.

I purposely left the bottom of the box open so the sawdust doesnt collect.
I also have a mark on the table saw deck notifying me when the sled has gone far enough to cut whatever is on the sled. But it is great advice.

 

[srmofo]

if you like wood working check out this woodgears.ca

The reader contributions is great. I especially like ron walters drill press table
if you make it back to the main site, the guy makes all kinds of crazy projects like cross bows and wooden gear machines

 

[Tribalvision]

if you like wood working check out this woodgears.ca

The reader contributions is great. I especially like ron walters drill press table
if you make it back to the main site, the guy makes all kinds of crazy projects like cross bows and wooden gear machines

I'm just starting with it and I enjoy it. I'll check the site out.. never too old to learn.... Thanks for the link!

 

[ctb]

if you like wood working check out this woodgears.ca

Looks like some good stuff on there. Thanks for the link.