How To Make Table Saw Sled: Improve Accuracy & Safety

A table saw sled is a jig that slides along the table saw’s miter slots, guiding workpieces past the blade with exceptional accuracy and safety. This article shows you how to build a table saw sled, improving your woodworking precision and making cuts safer.

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Why Build a Table Saw Sled?

A table saw sled offers several advantages over using the miter gauge or freehand cutting:

• Improved Accuracy: Sleds eliminate play and wobble, resulting in perfectly square cuts.
• Enhanced Safety: Keeps hands further from the blade and provides better control over the workpiece.
• Repeatable Cuts: Ideal for making multiple cuts of the same length or angle.
• Support for Large Pieces: Provides a stable platform for cutting large panels.
• Zero-Clearance Cuts: Reduces tear-out and splintering, leaving clean edges.

Table Saw Sled Plans: Design Considerations

Before you start building, it’s vital to plan your table saw sled design. Here are some factors to consider:

• Size: The table saw sled dimensions should suit your typical projects and the size of your table saw. A larger sled offers more support for bigger pieces, while a smaller sled is easier to store and maneuver.
• Miter Slot Dimensions: Precisely measure the width and depth of your table saw’s miter slots. This is crucial for making runners that fit snugly.
• Fence Configuration: Decide whether you want a single fence, a double fence, or an adjustable fence. A single fence is simpler to build, while a double fence provides greater support. An adjustable fence allows for angled cuts.
• Material Thickness: Choose materials that are thick enough to be stable and durable. The base should be flat and resist warping.
• Safety Features: Consider adding features like a handle, blade guard, and hold-downs to improve safety.

Table Saw Sled Materials: What You’ll Need

Choosing the right materials is essential for building a sturdy and accurate sled. Here’s a list of common table saw sled materials:

• Base: ¾” plywood or MDF (Medium-Density Fiberboard) are good choices for the base. They are stable, flat, and readily available.
• Runners: Hardwood like maple or oak, or UHMW (Ultra-High Molecular Weight) plastic. Hardwood is durable, while UHMW slides smoothly.
• Fence: Hardwood like maple, oak, or poplar. Choose straight, stable boards.
• Fasteners: Wood screws, glue, and optionally, bolts or threaded inserts.

Here’s a breakdown of material considerations:

Material	Pros	Cons
Plywood	Stable, readily available, affordable.	Can splinter, edges may need sealing.
MDF	Very flat, smooth surface, affordable.	Susceptible to moisture damage, edges can crumble.
Hardwood	Durable, stable, can be sanded smooth.	More expensive, may require more precise milling.
UHMW Plastic	Very slippery, durable, won’t swell or warp.	More expensive, can be difficult to glue.
Wood Screws	Easy to use, widely available, strong enough for most applications.	Can strip if overtightened, visible screw heads.
Bolts	Very strong, allow for disassembly.	Require drilling precise holes, can be bulky.
Wood Glue	Creates a strong bond, fills gaps.	Requires clamping, can be messy.

Building a Crosscut Sled: Step-by-Step Instructions

This section outlines the steps for building a basic table saw sled with a single fence. These steps can be adapted for different table saw sled designs.

Step 1: Prepare the Base

1. Cut the base to size. A common size is 24″ x 36″, but adjust based on your needs and table saw size.
2. Ensure the base is perfectly flat. If it’s warped, use a jointer and planer to flatten it.
3. If using plywood, seal the edges with edge banding or a few coats of finish to prevent splintering.

Step 2: Make and Install the Runners

1. Cut two runners to fit the miter slots. The runners should slide smoothly but without any play.
2. Use a router table or table saw to create a slight bevel on the bottom edges of the runners. This helps them slide more easily.
3. Apply glue to the runners and position them on the base.
4. Clamp the runners in place and let the glue dry completely.
5. Drill pilot holes through the base and into the runners.
6. Secure the runners with screws from underneath.

Step 3: Attach the Fence

1. Cut the fence to the desired length. It should be longer than the width of the base to provide ample support.
2. Ensure the fence is perfectly square. Use a square to check all angles.
3. Position the fence perpendicular to the blade path. Use a reliable square to align it.
4. Apply glue to the fence and clamp it to the base.
5. Drill pilot holes through the base and into the fence.
6. Secure the fence with screws from underneath.

Step 4: Cut the Kerf

1. Raise the table saw blade to its full height.
2. Carefully push the sled through the blade, creating a kerf in the base.
3. The kerf indicates the precise cutting line.

Step 5: Fine-Tune and Add Safety Features

1. Check the fence for squareness again after cutting the kerf. Adjust if necessary.
2. Add a handle to the sled for easier control.
3. Consider adding a blade guard to improve safety.
4. Apply a finish to the sled to protect it from moisture and wear.

Building an Accurate Table Saw Sled: Tips and Tricks

Achieving accuracy is crucial when building a table saw sled. Here are some tips to ensure your sled is as precise as possible:

• Use Precision Measuring Tools: Invest in a good quality square, measuring tape, and calipers.
• Mill Lumber Accurately: Use a jointer and planer to ensure your materials are flat, square, and true.
• Take Your Time: Don’t rush the building process. Accuracy is more important than speed.
• Test and Adjust: After completing each step, test the sled for squareness and accuracy. Make adjustments as needed.
• Use Shims: If you can’t get the fence perfectly square, use shims to fine-tune its position.
• Consider a Five-Cut Method: This method is especially helpful for building an angled sled. By using a five-cut method, you can compensate for small errors in squareness.

Table Saw Sled Fence: Types and Considerations

The fence is a critical component of a table saw sled. It provides a reference surface for the workpiece and ensures accurate cuts. Here’s a look at different fence types:

• Single Fence: The simplest design, consisting of one fence perpendicular to the blade.
• Double Fence: Two fences, one in front of the blade and one behind, providing greater support and stability.
• Adjustable Fence: A fence that can be adjusted to make angled cuts. This type is more complex to build but offers versatility.

When building a fence, consider these factors:

• Material: Use straight, stable hardwood like maple, oak, or poplar.
• Height: Make the fence tall enough to provide adequate support for the workpiece.
• Thickness: Ensure the fence is thick enough to resist flexing.
• Attachment Method: Use glue and screws to securely attach the fence to the base.

Making a Table Saw Sled for Beginners: A Simplified Approach

If you’re new to woodworking, start with a simple table saw sled design. Here’s a simplified approach:

1. Use a Single Fence: A single fence is easier to build and align than a double or adjustable fence.
2. Use Plywood for the Base: Plywood is readily available and relatively easy to work with.
3. Buy Pre-Made Runners: Instead of making your own runners, purchase pre-made UHMW runners that fit your miter slots.
4. Focus on Accuracy: Even with a simplified design, accuracy is still essential. Take your time and double-check your measurements.

Table Saw Sled Safety: Protecting Yourself

Using a table saw sled improves safety, but it’s still crucial to follow safety precautions:

• Wear Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.
• Use Push Sticks or Push Blocks: Keep your hands away from the blade by using push sticks or push blocks.
• Never Reach Over the Blade: Avoid reaching over the blade to retrieve cut pieces.
• Disconnect Power Before Adjustments: Always disconnect the power to the saw before making any adjustments to the sled or blade.
• Inspect the Sled Regularly: Check the sled for damage or wear before each use.
• Use Featherboards: Featherboards keep the wood tight against the fence, making for a safer cut.
• Dust Collection: Hook up a dust collection system to the table saw. Dust can cloud your vision, cause breathing issues and is combustible.

Optimizing Sled Performance

Once your sled is built, a few tweaks can enhance its effectiveness:

• Wax the Sled Base: Applying wax to the underside of the sled reduces friction, allowing for smoother operation. Paste wax or Teflon-based lubricants work well.
• Adjust Runner Fit: If the runners are too tight, sand them down slightly. If they’re too loose, add shims to eliminate play.
• Add a Stop Block: A stop block clamped to the fence allows for repeatable cuts of the same length.
• Incorporate Hold-Downs: Adding hold-downs keeps the workpiece firmly against the fence, preventing movement during cutting.
• Replace the Blade: A blade designed for fine cuts, such as a high-tooth-count blade, will reduce tear-out and improve the quality of your cuts.

Frequently Asked Questions (FAQ)

What is the best material for table saw sled runners?

Hardwood like maple or oak, or UHMW plastic are both excellent choices. Hardwood is durable, while UHMW slides very smoothly.

Can I use MDF for the table saw sled base?

Yes, MDF is a good option for the base because it’s flat and stable. However, it’s susceptible to moisture damage, so seal the edges.

How do I ensure the fence is perfectly square?

Use a precision square and check the fence for squareness after each step of the building process. Use shims to fine-tune the position if necessary.

What are the ideal table saw sled dimensions?

The ideal dimensions depend on your table saw and the types of projects you typically work on. A common size is 24″ x 36″, but adjust as needed.

Is a table saw sled safer than using a miter gauge?

Yes, a table saw sled is generally safer because it provides better support for the workpiece and keeps your hands further from the blade.

How important is table saw sled safety?

Table saw sled safety is very important because it provides better support for the workpiece and keeps your hands further from the blade. Safety measures such as using push sticks, blade guards, and wearing safety glasses are important.

Why does my table saw sled bind in the miter slot?

This is usually due to runners that are too tight. Sand them down slightly until they slide smoothly. Make sure to remove any dust or debris.

Can I use a table saw sled for cutting angles?

Yes, you can build a sled with an adjustable fence for cutting angles. This requires more complex joinery and careful calibration.