Table saw sled

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Project by xylophage posted 09-14-2011 04:11 AM 3711 views 2 times favorited 11 comments Add to Favorites Watch
Table saw sled
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I made this large sled because I have a cabinet job coming up that will require cross cutting a lot of large pieces of materials. Its over all length is 6 feet, and its depth is 27”. The fence is made out of three layers of 3/4” MDF. Its over all length is 4 feet, it’s 5” tall at the center and tapers down to 3”. I tapered the sled so that it would be heavy on the fence side. This way when your at the end of a cut the sled does not want to tip off the table saw.

The sled moves nicely, with no play in the runners. I did a four cut method to set the fence, and i have it consistently making square cuts that are within a few hundredths of an inch. I will have to admit that it is really large and heavy. I think that a sled any bigger would be dangerous and difficult to use.

-- D.A Winograsky

11 comments so far

View Routerisstillmyname's profile


763 posts in 4112 days

#1 posted 09-14-2011 04:28 AM

Nice job. Sure looks thick.

-- Router รจ ancora il mio nome.

View SalvageCraft's profile


274 posts in 3129 days

#2 posted 09-14-2011 04:52 AM

Nice job! I like how you tapered the base so it’s back heavy.
I made mine 3/4 thick, too. Just using what I had available, which was originally on a mobile base that came with my drill press. Due to the odd shape of the plywood base, I cut bevels on the ends of the fence to match (I think it makes it look a little bit greene and greene). I only put a fence/brace on the backside so that I could let wider stock hang off the front (then flip to finish the cut). This also makes storage a little easier, as it will slide into much tighter spaces. The kerf through the base ends about 4” from the front of the sled, so no front brace/fence is needed.

-- Jesse --

View smitty22's profile


714 posts in 3550 days

#3 posted 09-14-2011 06:03 AM

D.A., Looks like an extremely functional and useful tool.
You win the ‘monster sled’ award too!

Love the rear weight bias too, thanks for the idea.

-- Smitty

View Ken90712's profile


17819 posts in 3792 days

#4 posted 09-14-2011 12:01 PM

Well done!

-- Ken, "Everyday above ground is a good day!"

View timthetoolman's profile


41 posts in 3932 days

#5 posted 09-14-2011 01:10 PM

Good job on the sled. Looks like it will do the job for your cabinets. Maybe we should all be cutting out holes in our sleds to make them lighter and easier to handle. It works for aircraft. As the wood that is cut doesn’t actually move on the sled, so the holes really won’t be doing anything to the wood pieces as it passes the saw.

-- Tim The Toolman Dayton, Ohio

View Jim Jakosh's profile

Jim Jakosh

23740 posts in 3709 days

#6 posted 09-14-2011 03:08 PM

Wow, that is one nice sturdy sled…...............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View rmac's profile


224 posts in 3664 days

#7 posted 09-14-2011 05:24 PM

Darth Vader’s crosscut sled! Very cool.


-- My table saw laughs at hot dogs.

View longgone's profile


5688 posts in 3912 days

#8 posted 09-14-2011 11:27 PM

Very large, nice and solid looking sled. Looks like it takes 2 people to move it.

View doncutlip's profile


2832 posts in 4159 days

#9 posted 10-09-2011 01:32 AM

What is the “four cut method” for setting the fence?

-- Don, Royersford, PA

View Don Broussard's profile

Don Broussard

3849 posts in 2855 days

#10 posted 07-14-2012 04:52 PM

Good thinking on the weight bias. Stupid question: with 9/4” on the sled bottom, doesn’t that limit the thickness of cuts to about 7/8”?

-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!

View xylophage's profile


70 posts in 3137 days

#11 posted 07-14-2012 05:53 PM

No, the base of the sled is only 3/4” thick.

-- D.A Winograsky

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