Pen Blank Table Saw Sled Jig

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Project by LarryDNJR posted 05-25-2010 05:07 AM 9780 views 11 times favorited 8 comments Add to Favorites Watch

I made this little sled for my little Craftsman table saw. The main use will be for cutting pen blanks into small squares and pieces. I had a few angled stop blocks I’m working on to go with this as well. There is a little catch pit in the back for the small pieces they hit the back wall and bounce over to the “pit”. I might just add a small little angled piece near the back wall to help assist in the bounce direction toward the pit.

Wondering if I shouldn’t add a front wall on the opposite side of the blade. Maybe for stability.

Crafted from 1/2×2 x 2 Birch Plywood and scraps of what I believe is pine.

Base and rails are the Birch. The stop block, catch pit, back wall and work piece rest are the pine.

Using 2 BESSEY 4” VarioClippix Plastic Spring Clamp that have a jaw that slides open or close.

The back wall is glued and screwed to base with 6 drywall screws.

The rails on the bottom are glued as well. They were ripped from 1 end of the plywood. I laid aluminum foil in the two tracks and pressed the rails into place and aligned them. I covered them with some Titebond III Wood Glue and set the base plate down where I marked measurement points. This kept the rails fairly straight for me with very minimal play.

I debated to go and and put some small screws in to hold the rails. I’m wondering also if I could put something on the bottom or side of the rails to make it slide a tad bit smoother? A poly finish, wax, veneer?

At any rate it works fairly smooth much better than my first attempt at a sled. Rails were two short, it had way to much play left to right. The base was narrow, materials were junk, screws and rails misaligned. Last 2 pictures are of the original attempt.

-- ~Larry Columbus, OH

8 comments so far

View Richard's profile


11310 posts in 3948 days

#1 posted 05-25-2010 05:29 AM

That is one COOL Little Jig Larry. Keep doing this and pretty soon you’ll give away all your Secrets to “Master Pen Fabricating”...LOL….

P.S. I joined the I.A.P.T. Some Incredibly Beautiful Pens on there & Equipment Reviews. I REALLY like the “Pens For Our Troops”.I Think they are up to 10,000 Pens and Letters. GOOD STUFF!!


-- Richard (Ontario, CANADA)

View LarryDNJR's profile


209 posts in 4009 days

#2 posted 05-25-2010 05:32 AM

If I was a Master Pen Fabricator I wouldn’t mind sharing the knowledge. Only if I was long way to go. :(

Appreciate the compliment and encouragement though. :) lol

Yeah the I.A.P.T. has some awesome pens and information on there. I’ve been doing so much reading and learning about different techniques lately.

-- ~Larry Columbus, OH

View a1Jim's profile


118144 posts in 4492 days

#3 posted 05-25-2010 05:36 AM

View LarryDNJR's profile


209 posts in 4009 days

#4 posted 05-25-2010 05:36 AM

Thanks Jim

-- ~Larry Columbus, OH

View Eagle1's profile


2066 posts in 3980 days

#5 posted 05-25-2010 01:06 PM

Nice jig there. I would put a board on the back side of the sled. I had to put a bigger one on my regular,TS sled. The base started to warp a little.

-- Tim, Missouri ....Inside every older person is a younger person wondering what the heck happened

View LarryDNJR's profile


209 posts in 4009 days

#6 posted 05-25-2010 06:03 PM

Thanks Todd. Ya I bought the wood yesterday and started it. Was a few hour project considering glue up. I have a couple more ideas to implement on it and it’ll be what I want.

-- ~Larry Columbus, OH

View woodprof's profile


44 posts in 4105 days

#7 posted 05-27-2010 05:38 PM

“The main use will be for cutting pen blanks into small squares and pieces.” Help me with my confusion, Larry. What’s the purpose behind doing that? Are you making pieces from which to glue up laminated pen blanks? Or is there some other mysterious purpose that I’m too much of a newbie to get?

Thanks for any clarification.

View LarryDNJR's profile


209 posts in 4009 days

#8 posted 05-27-2010 06:42 PM

Yes and Yes. :)

Small squares for segmenting.

Plus lately I’ve been trying to figure out this 360 Herringbone design with minimal success.

I’ve done some regular Herringbone style glue ups that looked ok.

-- ~Larry Columbus, OH

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