Dead On, Totally Repeatable TS Sled

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Project by horky posted 06-08-2015 12:47 PM 57364 views 92 times favorited 23 comments Add to Favorites Watch


  • 1/2” ply base
  • 1/4” ply top
  • 1 1/4” poplar fences
  • Incra T-track and T-track plus
  • Incra precision racks and tape measure (have to add a right to left one and the final extension one on the right); allows for totally accurate and repeatable stop settings to 1/32”.
  • T-bolts and over sized holes to allow for fence adjustment with adjusting bolt (far right in second pic)
  • replaceable zero clearance inserts
  • walnut and MDF flip up stop block with 5/16” plastic bolts for clamping
  • two coats of poly on the bottom, then fully waxed
  • delrin miter bars, no slop, no seasonal movement
  • 36” long and will crosscut boards up to 18” wide

Used the 5-cut method to adjust the fence and am .001” to .002” off in 15”. I’ll call this Dead On.

Thanks for looking.

23 comments so far

View JimDaddyO's profile


680 posts in 4573 days

#1 posted 06-08-2015 02:42 PM

Very nice! It is great having something that is accurate and robust, it looks like you hit it out of the park on both counts.

-- You Tube channel:

View botanist's profile


167 posts in 5032 days

#2 posted 06-08-2015 03:34 PM

It looks great! My only concern is the lack of a guard on the back of the fence. Knowing my luck I’d forget and put my fingers in the path of the blade.

View Bill_Steele's profile


786 posts in 3225 days

#3 posted 06-08-2015 03:44 PM

That’s a very nice sled! I can tell that a lot of time went into the design in order to make it both functional and accurate. It looks like you have thought of all the details. I like the replaceable inserts and backer pieces—those will be very nice if you decide to tilt the blade or use a dado set (e.g. finger joints).

I have a couple questions: (1) Are the 4 slots on the top designed as part of some sort of hold down solution (e.g. t-bolt related)? (2) Why not build the sled wider to the left of the blade? It seems to me that if you crosscut with the sled more support on the left would be a good thing.

I’m going to add this to my watchlist, so that when I get around to building my own I will incorporate some of your clever ideas. Thanks for sharing.

View horky's profile


362 posts in 4424 days

#4 posted 06-08-2015 03:52 PM

Thanks for the comments. Here are answers to the questions:

  • Lack of guard where blade exists fence: did not forget this and it WILL be installed before putting into production use.
  • Slots in base: yes, these are for T-bolts and clamps, miter fences, etc.
  • Wider to the left: wanted to keep the weight down, now at 22#’s. Additional support can be obtained by putting a 3/4” sheet of ply just to the left of the sled, like a bench hook. Ditto for the right hand side if needed as well.

Final thought … I can/will add and extension fence/stop to the top t slot track. This will allow for repeatable longer cuts to the right … or left.

View bondogaposis's profile


6193 posts in 3845 days

#5 posted 06-08-2015 05:20 PM

Nice sled, it looks you will be able to make some nice stuff with it.

-- Bondo Gaposis

View Nels's profile


50 posts in 3122 days

#6 posted 06-08-2015 05:54 PM

big fan of delrin! Only used it for chair pads. Keeps the hardwood floor from getting beat up.

View Hazem's profile


292 posts in 2742 days

#7 posted 06-08-2015 06:12 PM

Horky, can u post a video and plans for this sled? I would like to make one myself. Thanks.

View nkawtg's profile


302 posts in 2745 days

#8 posted 06-08-2015 06:17 PM

I initially missed the adjustment screw at the bottom right of image #2, very nice detail. Can you provide more detail on that?

I love the sled and will be adding it to my favorites.

View lumberjoe's profile


2902 posts in 3742 days

#9 posted 06-08-2015 06:21 PM

Nice! I made something similar a few years back

Some observations I had with it:

1: I should have used and MDF base. The plywood-on-plywood lamination isn’t too happy.
2: I should have used (and went back and installed) threaded inserts. It only takes 3 or 4 change overs to strip screw holes out. I made 2 new sets, then just used inserts.

I like the adjustable fence, that’s a great idea


View RPhillips's profile


1330 posts in 3330 days

#10 posted 06-08-2015 07:21 PM

I’m very interested in making one like this too. I have one that I built following the William Ng video, but as you said, I find that I only have so much space and want to make a “jack of all _ ” sled. Love the fence idea… will be trying to dissect this when I’m ready to build another.

Nice work!

-- Rob - Indianapolis IN - Learning... one mistake at a time...

View Don K's profile

Don K

33 posts in 2614 days

#11 posted 06-08-2015 08:49 PM

Nice Sled. I like the replaceable inserts. Great Job!

-- v/r, Don -- Saw dust is 'MAN GLITTER' --

View Mean_Dean's profile


7057 posts in 4641 days

#12 posted 06-08-2015 11:57 PM

I don’t know man—off a thousandth of an inch…........

Just messing with you—that’s a great looking sled. Very useful, and is on my “To Do” list!

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View WoodNSawdust's profile


1417 posts in 2670 days

#13 posted 06-09-2015 12:32 AM

Great looking sled.

Would you elaborate on the back fence’s alignment system? Having the alignment on the back right I would assume that the back left is the pivot point and therefore a snug fit with the other bolts in oversized holes. What size bolts and how did you secure them on the bottom?

-- "I love it when a plan comes together" John "Hannibal" Smith

View SteveGaskins's profile


762 posts in 4081 days

#14 posted 06-09-2015 02:14 AM

Exceptional sled. Good job with the build.

-- Steve, South Carolina,

View Pointer's profile


465 posts in 2605 days

#15 posted 06-09-2015 02:44 AM

I do like how it extends out a bit so you don’t saw through it. Nice fence. Should have seen yours before I built mine. I too used the 5 cut method and got super close to dead on.

-- Joe - I am not entirely worthless, I can always serve as a bad example.

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