Woodworking TableSaw – Dizi Woods

Woodworking MegaSled

Woodworking MegaSled

Most fine woodworking woodworkers and carpenters have no less than one woodworking table saw sled. Having a table saw sled for woodworking can make work a lot more secure and additionally a well-thoroughly considered sled may likewise do significantly more.

Usually I call this one the “MegaSled,” or even sometimes the “Gigantic Sled,” because of its goliath estimation makes it so adaptable for any type of woodworking. As a matter of fact, it’s the correct stage for any assortment of woodworking joinery jig attachments. Since planning the sled I’ve added jigs for chopping miters, splines, tenons, finger joints and dovetails which would be perfect for type of fine woodworking, and I’ve plans for extra jig attachments sooner or later. It’s all potential because of the sled’s fence concept. In truth, you will see various particular and supportive alternatives as you build this woodworking table saw installation. On this article, I’ll focus on the woodworking sled itself; inside the ensuing test, I’ll cowl the jigs. How about we get begin!

Decrease the Woodworking Components

I don’t at times recommend beginning a woodworking challenge by cutting out the majority of the components. It’s regularly most prominent to cut each half as needed  in light of the fact that the test strikes nearby. However on this case, it’s less demanding to sort out the entire cutlist on the beginning.


As you do, utilize a pencil to mark each piece with its appointed letter from the nice woodworking chart above. I’ll resort to those letters as I’m going through this woodworking method.

Take care to cut each piece thoroughly and carefully. Confirm that your woodworking table saw’s cutting edge is perpendicular to the table. Square components must be sq., every one of their corners and on their edges. As you collect the endeavor, utilize a blend sq. to keep up everything genuine – extra care now will reimburse over the long haul with a right woodworking sled.

Moreover, select fantastic plywood for this woodworking project. While Baltic birch is all the time a wonderful choice for woodworking jig making, I’ve had great accomplishment with off-the-rack, hardwood-veneered plywood from the house center – anyway I don’t advocate development review plywood.

The Base

Most woodworking table saw sleds are produced from a single plywood panel, which is cut in half the primary time you employ the sled for woodworking. However I made this sled’s additional-giant base from two panels (P and Q on the drawings). As you’re employed on the 2 panels, understand that they’re mirror photographs of one another. As you lay out the dados, rabbets and slots, reference from the correct fringe of the appropriate panel and the left fringe of the left panel.

Start by slicing a pair of 1⁄2″-vast x about three⁄sixteen″-deep dados within the backside floor of every panel, utilizing the places offered within the accompanying diagram. Then flip the panels over and cut 1-1⁄2″-vast rabbets alongside what is going to turn out to be the 2 internal edges as soon as the sled is assembled. These rabbets must be deep sufficient that your 1⁄four″-MDF inserts will lay in them flush with the panel’s floor. It’s a good concept to cut them with a number of incremental passes, checking the depth with one of many inserts as you go.

Dados & rabbets. Plow the dados within the bottoms of base panels, then the rabbets on the highest inside sides.

Place the 2 panels in your benchtop with the rabbets dealing with upward and touching one another. Mark the sides nearest you as “entrance” and the other edges as “again.” Now use a 5⁄sixteen″ router bit to cut a slot down the middle of every of the 4 dados, starting 6-1⁄2″ from the entrance edge and four″ from the again edge of every panel. The slots are for the T-bolts.

Slots. Rout slots down the middle of the dados, creating a monitor for the shaft of your T-bolts to run in. You may also want to spherical off the entrance corners of the panels, although it’s not strictly essential.

When you have your 5⁄sixteen″ router bit useful, cut the slots within the fence extensions (A and B), centered 1-three⁄eight″ from the underside edge; they begin 6″ from the surface finish and terminate 1-1⁄2″ from the within finish of every half. Now set these apart and find the higher fence panel (O). Alongside certainly one of its edges, cut a rabbet to suit a piece of T-monitor. Most T-monitor is three⁄four″ extensive x three⁄eight″ deep, however take care to measurement the rabbet to your specific model.

Fence extensions. Maintain the slotted fence extensions shut by; you’ll quickly use them as spacers.

T-monitor rabbet. Measurement the rabbet within the higher fence panel rigorously in order that your T-monitor shall be flush with each the highest floor and the sting.

It’s time to start placing all of the elements collectively, so in case your two base panels have wandered off, return them to their former place on the benchtop, dealing with upward with the rabbets collectively. The fence help blocks (H-M) have to be positioned alongside the entrance fringe of the bottom panels.

Referencing from the left fringe of the bottom panel meeting, place one block 2-three⁄four″ away from that edge, one other eight-three⁄eight″ away and a third 14″ away. Place three extra of the blocks the identical distances from the correct fringe of your proper base panel meeting. This could depart just sufficient area between the 2 internal blocks to suit the fence guard (N).

Get it sq.. Guarantee your table saw sled will probably be correct in the long run by taking care to sq. the elements up throughout meeting.

Safe all of the blocks to the bottom panels with glue, taking care that they’re perpendicular to the entrance edge. Brad nails pushed from the underside of the bottom panels will maintain the blocks in place because the glue dries, however take care that the 2 halves remained aligned as you progress them round your woodworking bench top. At this level, solely the fence guard (N) holds the panels collectively. You possibly can add extra help by attaching the top piece (R) to the far aspect, centering it over the seam on the again edge between the 2 base panels.

Cautious now. As you progress issues round throughout meeting, needless to say the seam is supported solely by small blocks on every finish at this level, so take care!

The Fence

Subsequent you’ll connect the fence face panel (G) to the rabbeted fringe of the higher fence panel (O), rabbet-aspect up, as proven within the photograph under, left. Earlier than nailing the joint, make sure the seam is flush, and wipe away any glue squeeze-out. This shall be a essential floor of your sled’s fence.

The fence face panel (G) and higher fence panel (O) collectively make up what I’ll name from right here on out the fence panel meeting.

Fence panel meeting. Right here’s how the fence face panel and higher fence panel look when mixed to make the fence panel meeting.

Retrieve the slotted fence extensions (A and B). Place them on edge throughout the sled’s base towards the row of fence blocks, the place they’ll function momentary spacers. Now run a bead of glue on the highest edge of every of the seven fence help blocks (H-M), and alongside the decrease fringe of the fence face panel (G). Rigorously set the fence panel meeting on prime of the blocks, with the rabbeted panel dealing with upward. The glued fringe of the fence panel will contact the sled’s base just in entrance of the slotted “spacers.”

These two slotted elements ought to have the ability to slide easily out and in of the hole created. You don’t need them pinched in there too tightly – however you additionally don’t need any additional area.

From beneath the sled, shoot a few brads by way of the bottom panels up into the sting of the fence face panel to safe it in place.

Area out. Use your fence extensions as momentary spacers earlier than attaching the fence panel meeting.

Returning to the highest of the sled, verify the fence panel meeting for sq. earlier than the glue units up. If the face panel isn’t perpendicular to the bottom of the sled, nudge the rabbeted prime panel ahead or backward a tiny bit as wanted to right it. Lastly, take away the 2 fence extensions you’ve been utilizing as spacers…earlier than the glue dries they usually keep in there eternally.

Safe fence. Right here’s how the fence panel meeting seems as soon as it’s been secured in place (notice that I’ve already put in the T-monitor right here).

Now seize the extension helps (D and F). Fasten these to the underside edges of your fence extensions, as proven within the photograph at prime proper. Notice their location close to the ends farthest from the slots, and that the 2 ensuing assemblies are mirror photographs. Additionally, notice that open area on the slotted elements above the items you just related. There, glue the extension spacers (C and E) on edge, on prime of the extension helps. I feel it’s a good concept to shoot some brads by means of these help blocks from beneath to strengthen the joints. This completes what have now turn into your fence slide-outs. Slip them again into their slots on both aspect of the sled when the glue is dry.

Take a look at the mirror. The fence slide-outs have to be mirror pictures of one another.

Start the hardware set up by securing T-monitor within the rabbet on the fence panel meeting, and to the highest edges of the extension helps in your fence slide-outs. Don’t attempt to drive the screws with out first boring pilot holes! You danger spreading the plies within the fringe of the fence face panel beneath, compromising its clean and correct floor.

On monitor. After boring pilot holes, connect T-monitor to the fence and slide-outs.

Chuck a 1⁄four″ bit into a drill. Withdraw one of many slide-outs a few inches and place the bit within the middle of the slot, about 1″ from the top of the fence. Bore a gap via, then counterbore the opening from the opposite aspect so you possibly can slip a carriage bolt via the opening, finding its head under the floor of the fence face. Repeat these steps on the opposite finish of the fence, then safe each slide-outs with washers and wing nuts.

Bore & counterbore. Bore a 1⁄four″ gap within the middle of the slot, then counterbore from the other aspect to create an inset for the carriage bolt head.

Safe. The slide-outs are secured with wing nuts and washers.

Ending Touches

Minimize a number of additional replaceable inserts to slot in the throat of your sled, one on all sides of the kerf. You’ll be able to counter-sink three flathead woodworking woodscrews to carry every strip in place, preserving the screws as removed from the seam between the 2 strips as you’ll be able to in order that a woodworking sawblade won’t cut into them. By making the a variety of inserts forward of time, you possibly can be sure that the screw holes are in the identical location on every strip .

MDF throat inserts. Make a bunch of inserts now; that makes it simpler to make sure all of the screw holes are in the identical location – and also you gained’t be caught with out an insert once you want one. The inserts are secured with three flathead wood screws.

Since you took your time to construct the sled good and sq., mounting the runners is straightforward. Set your table saw’s fence 18″ from the blade. Place a strip of runner materials (MDF or excessive-density polyethylene) in every of your miter slots, shimming as wanted to convey the runners flush with the floor of your saw. Place a strip of woodworking double-sided tape on every runner. Now raise your sled over the saw and slowly decrease it onto the runners, retaining the aspect of the sled towards your table saw’s fence (you need to take away the slide-out on that aspect of the sled).

Rigorously flip the woodworking sled over then safe the runners extra completely to the underside with screws. I like to recommend utilizing #eight screws with giant pan heads. In case you bore enlarged holes (counterbored for the screw heads) by way of the runners, it is possible for you to to sq. the sled by shifting the runners – nevertheless, since you have been cautious as you constructed, no changes must be wanted.

Fenced in. Use your woodworking table saw fence to maintain the woodworking sled sq. to the saw blade when you place the sled onto its runners.

As a crosscut sled, the operation is self-explanatory. However we’re just getting began! Within the subsequent situation, I’ll present you methods to decorate and switch your crosscut sled into a Woodworking MegaSled! PWM

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