How to Build a Table Saw Sled

Building a table saw sled is simple and should still allow you to use the blade guard. It should take about two hours to complete this project. A table saw sled can make cutting materials on your table saw much easier, safer and more efficient. If you're not familiar with all tools being used, this project may be more difficult for you.

Things You'll Need

• 1/2” plywood
• 6”x60”x3/4” Alder wood
• 4”x26”x1” Alder wood
• 16”x2”x3/4” Maple wood
• 1” #8 wood screws
• Table Saw
• Band Saw
• Woodworker's glue
• Clamp
• Router
• Pan Head Screw
• Flat head screws

Instructions

1. Using the maple wood, cut two 16" strips that are about 3/4” wide and 3/8” thick. Create countersink holes for the screws where the first hole is 1” from the end of the strip and the next three are all evenly spaced apart.

2. Cut a 16”x26” 1/2” thick piece of plywood for your sled. Place strips in grooves of table saw, countersinks facing down with first hole showing off the back end of your table saw, and set the fence 2” from the right groove edge. Place the sled on top of the strips so it is up against the fence and use one screw to secure the strips to the sled through the first hole of each strip. Repeat process on opposite side of table saw. Remove the sled with attached strips and finish screwing through all countersink holes.

3. Cut a piece of Alder wood so you have 2 3/4” pieces that are 26” long each. Stack them on top of each other, line them up and then glue and clamp them together. Using the table saw, cut from the left hand side about 3” line to 5” mark and from the right hand side 3” line to 11” mark. Use a router, after drawing curves on the top chunk, to round the top corners.

4. Working 1” from back left corner of sled, route a 3/32” slot through the sled and a 1/2” wide second groove over the slot. The groove should only be 1/8” deep into sled and not go all the way through. Starting from the right edge of the side of the sled that the back fence will attach to create countersink holes 1/2” in from sled edge and one hole every 6” along the same edge. Line the back fence up on the sled and screw the 1st hole on the right edge in. Place the pan head screw tight enough so the back fence won't turn, but loose enough so it will move when tapped.

5. Lower the table saw blade all the way down and place sled on table saw. Slowly turn on the table saw, hold sled in place and move the blade up until it is at its full height. Turn blade off. Using square ruler, place one side of ruler against table saw blade and other against back fence creating a perpendicular line between the two. Remove sled and tighten the pan head screw completely.

6. Use flat head screws to fully attach the back fence to the sled through remaining countersink holes. Place the table saw sled on the table saw and check the alignment by cutting a piece of wood.

Tips & Warnings

• Double check your work throughout entire process to be sure everything is being measured and cut correctly.

• Whenever you're working with wood cutting tools, always use proper safety precautions and work in a well-lit, well-ventilated area.