SuperSled for Table Saw

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Project by HorizontalMike posted 12-21-2011 01:41 AM 51491 views 219 times favorited 67 comments Add to Favorites Watch

This has been an interesting project for me to research as well as to build, in that I sure had my challenges with the router. ;-) I not only read/watched everything that Eagle Lake Woodworking has on this table saw sled design and build, I also looked elsewhere for tips and techniques to make my execution/build of this project as accurate as possible. Stevin Marin has a neat YouTube Video on accurately aligning and installing runners and fences that I found useful as well. Armed with this information I was off to the shop and making dust!

Some of the modifications that I made include:

++ Used 3/4in plywood for base— I want more durability/longevity and besides I can still cut 2 1/4in even with this thick of base ;-)

++ A 56in long main fence— I wanted to be able to cut multiple pieces as long as 36in long so I made the fence on the left stick out 38in to include a stop block as well. Do note the gap in the vertical T-Track on the main fence so that the TS blade doesn’t have to cut through the T-Track.

++ I moved the “adjustable” fence slots closer together than the original plans called for as well— The plans called for the slots to be 7 1/2in apart, however, I found that only got me down to a max/min angle of ~60/30 degrees. I made the slots just 6in apart and when finished I can actually get a max/min angle 70/20 degrees, so that 22 1/2 degree angle is a doable on this sled.

++ I surface mounted the T-Track on the “adjustable” fences instead of routing them flush here— I did this in order to NOT have to depend on just 1/4in of material to hold down the T-Track. This works fine and does NOT try to pull the T-Track away from what it is mounted to.

++ I added the second “main fence” T-track as recommended on Eagle Lake WW Improvements— I did, however, move the vertical facing T-Track down to mid-board as in the Stevin Marin video. I think that will work better in that position.

++ Added a second “round-over” piece to the push/pull handle— I had this left over from making a longer piece for my handle needs and decided to use the leftovers as well. In the second image you can see a lower round-over piece on the handle that I placed there to keep my thumb from migrating any closer/lower toward the blade than it needed to be. It seems to serve as a tactile reminder of where to keep my thumb when pushing/pulling the sled.

Oh, I almost forgot the most FUN that I had… I FINALLY joined the world of air tools with my first ever Ridgid #18 Finishing/Brad Nail Gun. Having never used one before, I was amazed at what I had been missing all these years… sounds stupid but wow! I now have that third hand that I never had before to hold things in place for gluing/screwing more sturdy joints. I only used the minimum amount of brads to hold but really, really, really wanted to just keep hammering away with this tool! 8-) Kind of felt like getting that driving license at 16 and the freedom and greater possibilities that that represented.

I will eventually add more images on my own website once my web hosting service repairs/resets their domain server, so stay tuned if interested.

-- HorizontalMike -- "Woodpeckers understand..."

67 comments so far

View Jim Jakosh's profile

Jim Jakosh

26629 posts in 4316 days

#1 posted 12-21-2011 01:44 AM

Man that is a “killer” sled. I love it!!

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

View Lance's profile


428 posts in 3736 days

#2 posted 12-21-2011 01:48 AM

Awesome SLED! I need one of these so bad!

-- Lance, Hook'em HORNS! ""V""

View oxyoke's profile


57 posts in 3564 days

#3 posted 12-21-2011 02:02 AM

I feel the same way after every tool that I aquire . Will this need ever go away and will my beautiful better half ever understand the relationship I have with my tools? great table saw sled.

-- Bill Byron Center MI

View robert triplett's profile

robert triplett

1566 posts in 4315 days

#4 posted 12-21-2011 02:08 AM

Should I finally build one of these or wait for someone to make it even more perfect? I guess I should order some T-track. Thanks for the great pictures and description.

-- Robert, so much inspiration here, and now time to work!!!

View HorizontalMike's profile


7933 posts in 4124 days

#5 posted 12-21-2011 02:15 AM

Hey Robert,
I went through four 8-foot sticks of T-Track to build this sled AND my horizontal mortising machine. I have about 6in of T-Track left in four pieces. FYI, I think the sled took about one full 8ft stick PLUS ~6ft of the second stick. I actually had to salvage two 1ft pieces from a mistake I had made on the mortising machine earlier, but it worked out in the end. ;-)

-- HorizontalMike -- "Woodpeckers understand..."

View b2rtch's profile


4921 posts in 4259 days

#6 posted 12-21-2011 02:25 AM

Mike, I have a hard time believing that you new to wood working, every ioen of your projects seems to be perfectly executed.
I have been thinking about building one of them for several years but I never really found a real need for one. I have a panel sled and a crosscut sled and it seems that this all I need for now.
Thank you for all the pictures and explanations.

-- Bert

View a1Jim's profile


118201 posts in 4787 days

#7 posted 12-21-2011 02:38 AM

Very cool mike a sled on steroids,great job


View jaylost's profile


56 posts in 3560 days

#8 posted 12-21-2011 02:42 AM

I think i need one of those.. Might start researching this myself.

-- " If it wont fit just hit it harder "

View choppertoo's profile


304 posts in 4523 days

#9 posted 12-21-2011 03:35 AM

I’ve got a sled and a separate miter sled already but when I redo them in the near futuer I will use this as my starting point. Very nice! Thanks for the information and the links.


-- The greatest danger for most of us is not that our aim is too high and we miss it, but that our aim is too low and we reach it.. Michelangelo

View live4ever's profile


983 posts in 4220 days

#10 posted 12-21-2011 04:25 AM

Awesome! I’ve got to build one of these and will take a close look at your improvements when I do. How are you storing yours?

-- Optimists are usually disappointed. Pessimists are either right or pleasantly surprised. I tend to be a disappointed pessimist.

View gfadvm's profile


14940 posts in 3900 days

#11 posted 12-21-2011 04:32 AM

Great job, Mike. I knew you could do it! I routed T tracks instead of buying t track to save a few $ but otherwise our sleds are very similar. You will really enjoy this for a lot of years. Now that you have a brad nailer, you need to get a finish nailer and pin nailer to complete your set. They are fun and really useful for a lot of projects. An air sander and die grinder are next if you have the compressor capacity. I love my air tools. Have you made some test cuts to make sure your fence is dead square? Enjoy.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View Grandpa's profile


3264 posts in 3886 days

#12 posted 12-21-2011 05:11 AM

Outstanding job on a great looking sled. You have outdone yourself.

View sras's profile


6317 posts in 4339 days

#13 posted 12-21-2011 05:24 AM

Looks like you did a great job! Nothing like a good sled to make those cuts easier!

-- Steve - Impatience is Expensive

View ellen35's profile


2750 posts in 4643 days

#14 posted 12-21-2011 05:45 AM

Very impressive… you might have a market for these!

-- "Don't let the perfect be the enemy of the good." Voltaire

View Dusty56's profile


11863 posts in 4898 days

#15 posted 12-21-2011 05:48 AM

Talk about SWEET !!
First class project , HZMike : )

-- I'm absolutely positive that I couldn't be more uncertain!

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