How To Make A Sled For A Table Saw: Accuracy & Safety

A table saw sled is a simple jig that dramatically improves both the accuracy and safety of your table saw, allowing you to make perfect crosscuts and other precise cuts. What is a table saw sled? It’s a platform that rides in the miter slots of your table saw, providing a stable and controlled way to push your workpiece past the blade. This article provides a comprehensive guide on building a high-quality sled.

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Why Build A Table Saw Sled?

Before we dive into the build, let’s explore why a table saw sled is an essential addition to any woodworker’s shop.

• Improved Accuracy: A sled minimizes tear-out and produces exceptionally clean and square cuts. It’s far more accurate than using the miter gauge alone. This directly addresses the need to improve table saw accuracy.
• Enhanced Safety: By holding the workpiece securely and keeping your hands away from the blade, a sled significantly reduces the risk of kickback and other table saw accidents.
• Small Parts Cutting: Sleds are ideal for safely cutting small or awkward pieces that would be difficult or dangerous to handle otherwise.
• Repeatable Cuts: Set up stops on your sled to make perfectly repeatable cuts, saving time and ensuring consistent results.
• Miter Saw Alternative: A well-built table saw sled can often replace a miter saw for many crosscutting tasks. Sleds offer superior accuracy and capacity for some cuts compared to a miter saw.

Choosing Your Design: Table Saw Sled Plans

Finding the best table saw sled design for you depends on the size of your table saw and the types of projects you typically work on. Here are a few popular styles:

• Basic Crosscut Sled: The most common type, designed primarily for making accurate 90-degree crosscuts.
• Miter Sled: Features an adjustable fence that allows you to make precise miter cuts at any angle.
• Small Parts Sled: Specifically designed for safely cutting very small pieces of wood.
• Large Capacity Sled: A larger sled to handle wide panels and boards.

Before starting, look over some table saw sled plans. Many free plans are available online. Consider your specific needs and adapt the plans accordingly.

Key Considerations for Sled Design

• Size: The size of your sled should be appropriate for the size of your table saw and the types of cuts you’ll be making.
• Fence Height: A taller fence provides better support for taller workpieces.
• Adjustable Fence: An adjustable fence allows you to make accurate miter cuts.
• T-Tracks: Adding T-tracks to your fence allows you to easily attach stops and other accessories.
• Zero Clearance: A zero clearance sled reduces tear-out and provides a cleaner cut by supporting the wood fibers right up to the blade.

Materials and Tools

Here’s what you’ll need to start building a table saw sled:

• Plywood: 3/4″ plywood is generally recommended for the base and fence. Baltic birch plywood offers exceptional stability and flatness, but any good-quality plywood will work.
• Hardwood Runners: Choose a hardwood like maple or oak for the runners that will fit into your table saw’s miter slots.
• Screws: Use wood screws to assemble the sled. Choose the length based on material thickness.
• Wood Glue: High-quality wood glue will create a strong and durable bond.
• Finishing Supplies (Optional): Polyurethane or paste wax can help the sled glide smoothly.

Tools:

• Table Saw (obviously!)
• Measuring Tape
• Combination Square
• Clamps
• Drill and Drill Bits
• Countersink Bit
• Sander and Sandpaper
• Safety Glasses
• Hearing Protection

Step-by-Step Crosscut Sled Tutorial

Let’s walk through a detailed crosscut sled tutorial:

Step 1: Prepare the Runners

1. Measure Miter Slots: Accurately measure the width and depth of your table saw’s miter slots. A digital caliper is ideal for this.
2. Cut Runner Stock: Cut two pieces of hardwood slightly wider and thicker than your miter slots.
3. Mill Runners to Size: Using your table saw or a planer, carefully mill the runners to fit snugly but smoothly in your miter slots. The runners should slide freely without any slop. A tight fit is crucial for accuracy.
4. Test Fit: Continuously test the fit of the runners in the miter slots as you mill them down. The goal is a perfect, friction-free fit.

Step 2: Cut the Sled Base

1. Determine Sled Dimensions: Decide on the table saw sled dimensions that suit your needs. A good starting point is around 24″ deep and as wide as your table saw’s table.
2. Cut the Base: Cut the plywood base to the desired dimensions. Ensure the edges are square and clean.

Step 3: Attach the Runners

This step is critical for building an accurate table saw sled.

1. Position Runners: Place the sled base on your table saw. Insert the runners into the miter slots.
2. Apply Glue: Apply a thin layer of wood glue to the top of each runner.
3. Attach Runners to Base: Carefully position the base on top of the runners, ensuring they are flush with the front edge of the base.
4. Clamp and Secure: Clamp the base to the runners, ensuring the runners remain aligned within the miter slots.
5. Drill Pilot Holes: Drill pilot holes through the base and into the runners. Use a countersink bit to create space for the screw heads.
6. Attach with Screws: Secure the runners to the base with screws.

Step 4: Cut the First Fence

1. Cut Fence Stock: Cut a piece of plywood for the rear fence. A height of 3-4″ is usually sufficient.
2. Attach Rear Fence: Apply glue to the edge of the sled base where the rear fence will be attached.
3. Square the Fence: This is the most important step for ensuring accurate cuts. Use a large square to ensure the fence is perfectly square to the miter slots. Double-check with a reliable square.
4. Clamp and Secure: Clamp the fence firmly to the base, maintaining the square alignment.
5. Drill Pilot Holes and Screw: Drill pilot holes and secure the fence with screws.

Step 5: Cut the Kerf

1. Raise Blade: Raise your table saw blade to its full height.
2. Carefully Cut Kerf: Slowly and carefully push the sled through the blade, creating a kerf through the base. The kerf represents the path of the blade.

Step 6: Attach the Front Fence

1. Cut Fence Stock: Cut the front fence to the same dimensions as the rear fence.
2. Position the Fence: Place the front fence on the sled, aligning it with the kerf.
3. Apply Glue: Apply glue to the edge of the base where the front fence will attach.
4. Clamp and Secure: Clamp the fence to the base.
5. Drill Pilot Holes and Screw: Drill pilot holes and secure the fence with screws.

Step 7: Fine-Tuning (Critical for Accuracy)

1. Test for Square: Use a reliable square to check the accuracy of the sled. Cut a piece of scrap wood and check it for square using the “five-cut method”.
2. Adjust if Necessary: If the sled is not perfectly square, you can shim the rear fence slightly to adjust the angle. Loosen the screws on the rear fence, insert shims (thin pieces of paper or veneer) between the fence and the base, and re-tighten the screws. Re-test until you achieve perfect squareness.
3. Add T-Track (Optional): Install T-tracks in the fence for attaching stops and other accessories.

Step 8: Finishing Touches

1. Sand Edges: Sand all edges of the sled to remove any sharp corners or splinters.
2. Apply Finish (Optional): Apply a coat of paste wax or polyurethane to the base to help the sled glide smoothly over the table saw surface.

Enhancing Safety

• Always Use Push Sticks: Never place your hands directly in the path of the blade. Use push sticks or push blocks to guide your workpiece.
• Secure Workpiece: Ensure your workpiece is firmly against the fence before making a cut.
• Slow and Steady: Push the sled through the blade at a slow and controlled pace.
• Never Reach Over the Blade: Avoid reaching over the blade while the saw is running.
• Unplug Before Adjusting: Always unplug your table saw before making any adjustments to the sled or blade.

Advanced Techniques and Add-ons

• Adjustable Stop Blocks: Add adjustable stop blocks to the fence for making repeatable cuts.
• Hold-Down Clamps: Use hold-down clamps to secure your workpiece firmly to the sled.
• Miter Attachment: Build a miter attachment for making angled cuts. This can greatly increase the versatility of your sled.
• Dust Collection: Integrate a dust collection system into your sled to keep your shop clean and improve visibility.

Troubleshooting

• Sled Sticks or Binds: Ensure the runners are properly fitted to the miter slots. Wax the runners for smoother movement.
• Cuts Not Square: Carefully check and adjust the fence alignment. Use the five-cut method to fine-tune accuracy.
• Tear-out: Ensure the blade is sharp and the wood is well-supported. A zero clearance sled helps minimize tear-out.

Table: Comparing Table Saw Sled Designs

Feature	Basic Crosscut Sled	Miter Sled	Small Parts Sled	Large Capacity Sled
Primary Use	90-degree cuts	Angled cuts	Small parts	Wide boards/panels
Fence	Fixed	Adjustable	Fixed, often short	Fixed
Size	Medium	Medium/Large	Small	Large
Complexity	Low	Medium	Medium	Medium/High
Accuracy	High	High (if tuned)	High	High
Safety	High	High	Very High	High

FAQ

• Can I build a sled without a table saw? Yes, but it’s more challenging. You’ll need alternative tools for cutting the base and runners accurately.
• What is the best material for sled runners? Hardwood, like maple or oak, provides the best stability and durability.
• How do I make my sled perfectly square? The five-cut method is the most reliable way to check and adjust the squareness of your sled.
• How often should I wax my sled? Waxing frequency depends on usage. Wax whenever the sled starts to feel sticky or doesn’t glide smoothly.
• Is a table saw sled a good miter saw alternative? Yes, for many crosscutting tasks, a table saw sled can be more accurate and versatile than a miter saw.

By following these steps and paying attention to detail, you can build a table saw sled that will improve the accuracy, safety, and enjoyment of your woodworking projects. Embrace the process and make it your own – DIY table saw sled building is a rewarding experience!