Crafting A Custom Rip Sled For Your Table Saw: A Diy Guide

A table saw sled is a must-have jig for your table saw. It makes cutting wood against the grain safer and easier, and can be used to cut very small pieces without the fear of injuring yourself. You can build a simple cross-cutting sled with scraps of wood and a few precise cuts, and it will still achieve accurate cuts.

To build a table saw sled, you will need a few essential tools and materials. These include a drill, drill bits, plywood, and a straight piece of hardwood. The process involves measuring and cutting the wood to the correct size, assembling the pieces with glue and screws, and fine-tuning the sled for accuracy.

By following these steps and making the necessary adjustments, you can create a functional and safe table saw sled that will enhance the capabilities of your table saw.

Cut plywood to size for the base and fences

To build a rip sled for a table saw, you'll need to cut your plywood to size for the base and fences. The size of your rip sled will depend on the size of your table saw and the capacity you require.

For the base, you can use a large piece of plywood, typically around 1/2" or 3/4" thick. Cut the plywood to your desired length and width, ensuring it's slightly larger than the material you plan to cut. For example, if you want to cut a 24" panel, your base should be at least 24" deep.

For the fences, you can use plywood strips, typically around 3/4" thick. Cut the strips to the desired length, allowing for some overhang at the back of the base. You may also want to cut one end of the long back fence square, using the table saw sled base as a guide for the other cut. The length of the short fence is less critical, and you can cut both ends square.

Remember to consider the size of your table saw and the capacity you need when cutting your plywood to size. You may also want to laminate multiple layers of plywood together for a stronger and straighter fence.

Make runners from hardwood or plywood

To make runners for your table saw sled, you'll need to cut strips of hardwood that fit into your table saw's miter gauge slots. Here's a step-by-step guide:

Step 1: Check the Size of Your Miter Gauge Slots

Almost all table saws have a standard miter track dimension of 0.75" wide x 0.375" deep. However, it's best to check and determine your miter track dimensions before making any cuts. Use digital calipers to get accurate measurements.

Step 2: Cut a Hardwood Board to Fit the Slots

Use a hardwood board, such as oak, as it's a dense and durable wood that's not prone to warping. Cut the board to fit snugly into your miter gauge slots. Sand or plane the board until it slides easily in the slots without any slop or play.

Step 3: Test the Fit

Place the cut hardwood into the miter track to test the fit. It should slide smoothly without sticking or wiggling. If there is any play or sticking, sand the hardwood until you achieve a snug fit.

Step 4: Prepare the Plywood Base

Cut a piece of plywood to serve as the base of your sled. The size of the plywood base will depend on your desired sled size. Place the hardwood runners onto the miter slots and position the plywood base on top, ensuring it's approximately square to the track and centered with the saw blade.

Step 5: Attach the Runners to the Plywood Base

Apply a small amount of wood glue along the length of the hardwood runners. Place the plywood base on top of the runners, ensuring it's aligned properly. Add weight to the plywood and let the glue dry overnight.

Step 6: Secure with Screws

Once the glue has dried, flip the assembly over and drill pilot holes along the length of the hardwood runners. Countersink the holes so that the screw heads are inset and don't hinder the movement of the sled. Screw the runners to the plywood base, ensuring a firm attachment without stripping the wood.

Now you have your table saw sled runners made from hardwood and plywood! You can continue with the rest of the steps to build your table saw sled, following any of the guides available online.

Drill and glue runners to base

Now we've cut our runners to size, we need to attach them to the base. This is a crucial step in building your rip sled, as the runners will guide the sled along the miter slots of your table saw. Here's a step-by-step guide to drilling and gluing the runners to the base:

• Place your runners into the miter slots of your table saw. You can use washers or pennies to raise the runners slightly above the table surface. This ensures the sled will glide smoothly.
• Apply a thin bead of wood glue or super glue along the center of the runners. Be careful not to use too much glue, as it may spill onto the table saw.
• Place the base on top of the runners, making sure it's square to the table saw fence and aligned with the center of the blade.
• Add weight to the base and let the glue dry. You can use clamps or weights like paint cans to hold the base in place while the glue sets.
• Once the glue is dry, remove the assembly from the table saw and flip the base over.
• Drill pilot holes along the length of the runners and countersink the holes. This is important to ensure the screw heads don't protrude above the surface of the runners, which could hinder the movement of the sled.
• Secure the runners to the base with screws. Use screws that are long enough to hold the base and runners together firmly, but not so long that they protrude through the bottom of the base.
• Test the sled by sliding it back and forth in the miter slots. If there is any binding or sticking, adjust the runners by sanding the areas that are rubbing.

By carefully following these steps, you'll have a solid and smooth foundation for your rip sled, ensuring accurate and safe cuts with your table saw.

Square fence to blade, glue and screw

To square the fence to the blade, you must first raise the blade. Then, press a framing square against the blade and swivel the fence on a single screw at one end. Clamp the opposite end when the fence is square to the blade.

Now, glue and screw the stiffener to the front edge of the base, ensuring that the screws are kept away from the path of the table saw blade. Set the table saw blade to around 3/4 inch and slide the base into the blade, stopping when you are within 3 inches of the back of the base. Turn off the saw and wait for the blade to come to a complete stop before removing the sled.

Align the fence with the back edge of the base and drive a screw into the right end. You can also use a tri-square to ensure the fence is flush against the blade. Reposition the tri-square on either side of the blade to double-check the back fence for squareness. When satisfied, allow the glue to dry overnight before moving.

Test sled for accuracy

Test your sled for accuracy

Now that you've built your table saw sled, it's time to test it for accuracy. Here are the steps to follow:

• Cut a piece of scrap wood using your sled.
• Flip the piece of wood over and line up the freshly cut edge with the fence.
• Make another cut, this time removing a small amount of material.
• Repeat this process, cutting all four sides of the scrap wood.
• After cutting all four sides, make a final cut along the first side, this time making a larger cut.
• Use a caliper to measure the top and bottom of the off-cut.
• Compare the measurements to check the accuracy of your sled. If there is a significant difference, you may need to adjust the fence or make other minor adjustments.

By following these steps, you can ensure that your table saw sled is accurate and ready for use.

Frequently asked questions