Save-Your-Time Saw Sled
I made this sled for my table saw a few years back and wanted to share it with my new friends at the RouterForums.com. I wanted to incorporate allot into this sled so I started with having a good way to measure repeatable cuts, angle cuts, & miter cuts without making the sled itself too big.
I just slightly off-centered where the blade goes on the sled in order to put a stop block to the left of the blade that would go to 18”. To get the most out of this aspect of the sled I made a 1” thick block for the table saw fence and can cut anything up to 35” by just adding an inch to my table saw fence measurement on the right side of the blade.
I rounded over for the places where your hands go on the back fence, staining it with a gun stock stain and finished the handles with 2 coats of wipe on gloss poly. I used a “bolt down” method for the back fence of the sled as I find this the most accurate way of finding 90 degrees to the blade when calibrating it. I put a 3” wide zero clearance insert made from hardboard that can be unscrewed and easily slips out of it’s space to accommodate straight cuts, 45 degree cuts, and various size dado cuts (1/4, 3/8, 1/2, & 3/4 inch) all with their own insert. I have changed the inserts out many times and I am still able to use the same screw holes for holding them in and will just move them up or down when the ware out. I finished the sled off with miter fences that include stop blocks.
All hardware was purchased during a really good super sale Rockler was having while I got the nuts and bolts for the fence at the big box store and the rest was made from scrap material in the shop.
This sled is without a doubt the most useful jig I've made as I use it all the time. It saves me so much time as very little setup is needed to make crosscuts.
-- -- "Never underestimate the power of a kind word, a good deed, or a table saw." -- --