Weekend Table Saw Enhancements

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Project by jaysuzi posted 09-19-2014 11:30 PM 7275 views 20 times favorited 9 comments Add to Favorites Watch

This past weekend I decided to do some much needed table saw enhancements. All the projects were done with scraps I had around the shop.

I already had a table saw sled, but was not quite happy with it.
1. the runners had a small bit of play in them – the new ones are perfect. nice snug – but not too snug
2. the old fence was made from some pre-milled oak – but it wasn’t as flat as it should have been – the new one is made from MDF and seems to be as straight as my straight edge. I used the old front fence to be the back fence on my new sled.
3. the old one was made from a 2 ft wide sheet of mdf, so with the front and back fence, I could only cut about a 20 inch wide panel. I wanted to be able to cut a full 2 ft panel – which I can on the new one
4. The old one wasn’t bad on the 5 cut test, but this one is just about dead on
5. The old one had 1 inch and 1/2 in markings. I did the same on this one. This is very handy for those projects that don’t need to be dead on accurate.

After making that, I had some left over runners, so I made a miter sled – following Steve Ramsey’s video.

I then made a spline cutting jig. I have a project coming up where I need to put some splines in, so this will come in handy. – the markings on this are just because it is made from scraps from my old table saw sled.

Finally, I made a new zero clearance insert. I was not happy with the fit of my old one and had actually gone back to the manufactures insert. I am much happier with this one.

-- Jay in Pennsylvania,

9 comments so far

View woodcox's profile


2386 posts in 2815 days

#1 posted 09-20-2014 12:51 AM

Nice Jay. Do you make your own runners or buy them? I made my first quick and dirty sled the other day and you have some good ideas here I should use for my next go at them.

-- "My god has more wood than your god" ... G. Carlin.

View Nowater's profile


18 posts in 2744 days

#2 posted 09-20-2014 02:46 AM

Nice. I like the measurements on the sled-why didn’t I think of that.

View InsideTheBox's profile


124 posts in 2478 days

#3 posted 09-20-2014 03:58 AM

You said “I made a new zero-clearance insert…” like it was no big deal…. Dang, how are the rest of us novices supposed to keep up with this kind of skill??? (long, heavy sigh)

Seriously, that is very cool. All of them.

-- There's no such thing as a mistake; only a quick change of plans.

View TheWoodenOyster's profile


1335 posts in 2738 days

#4 posted 09-20-2014 11:42 AM

All looks good. I have never thought about putting marks on my sled for non-fine woodworking projects. I might do that.

-- The Wood Is Your Oyster

View OldWrangler's profile


731 posts in 2398 days

#5 posted 09-20-2014 12:11 PM

The measuring marks are a great idea. Gotta fix up my sled with some. Nice sleds.

-- I am going to go stand outside so if anyone asks about me, tell them I'M OUTSTANDING!

View calisdad's profile


334 posts in 2313 days

#6 posted 09-20-2014 02:08 PM

Plus 4 on the increment marks. How did that slip by so many sleds that were made?

-- Groveland, CA.

View a1Jim's profile


118084 posts in 4381 days

#7 posted 09-20-2014 02:51 PM

These will make your projects so much easier and quicker too.


View jaysuzi's profile


150 posts in 2604 days

#8 posted 09-20-2014 07:52 PM

Nice Jay. Do you make your own runners or buy them? I made my first quick and dirty sled the other day and you have some good ideas here I should use for my next go at them.

- woodcox

Yes, I made my own runners out of some scrap hardwood. The following is the ultimate in sled videos:

About 15 minutes in, he gets into making the runners. I am not perfectionist like William, but followed his advice and got them really close. A few of them I had to touch up with some sandpaper.

-- Jay in Pennsylvania,

View Roger's profile


21030 posts in 3607 days

#9 posted 09-06-2015 12:15 PM

All gr8 additions to any table saw

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

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