Sliding 45 Deg Sled

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Project by Karson posted 09-16-2012 11:16 PM 6869 views 14 times favorited 20 comments Add to Favorites Watch

I was bringing back to life a Grizzly table saw that I’ve had buried for about 9 years It was missing everything (wings, fence, blade, washer, nut, plate, dust collector door) I got a fence at a going out of business Woodworkers Warehouse about 8 years ago, some wings at a Grizzly Tent sale.

I setup the blade stops and was ready to make some boxes.

But first I needed a sliding sled.

I’m using a 3/4” piece of Phenolic Plywood 13 layers. The front is 2 X 3” Sapele the back is 1 1/2 X 2 1/2” Sapele. The back is screwed directly to the table surface with 2” stainless screws. The front is bolted on one end and a tempory screw holds the other end until the fence is calibrated at a 90 degree cut then another bolt is inserted at the other end and more screws bring it tight to the Phenolic surface.

I got another piece of Sapele that was the required width to make the jig track flush with the front fence. A third piece of Sapele was attached as a blade guard in the front. Two sliding tracks fit in the table saw slots. The saw cut is a 45 deg bevel.

The fence stops are wooden hinges made with the Incra Hinge Crafter and are attached to the track with brass Toilet bolts and 3 wing knobs. I glued an insert that is tight on the track and keeps the hinge stop from rotating when in use. I made two stops so that one is set for the width and the other for the length. I use the stops on the left of the blade so the first 45 degree cut is made with the hinges in the up position. Then the board is rotated and the knife edge on the cut is off the surface so that it can’t slip under the end stop.

By using two stops it’s easy to make all sides the correct length. One for the width and the other for the length.

The front edge on the stops fit tight against the front fence and is about a couple of thousands long so it slightly lifts the stop when it’s in the down position.

With the 45 degree stop set on the saw accurately I just angle the blade and cut away. everything fits tight.

The spline cutting jig is written up here

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

20 comments so far

View sedcokid's profile


2738 posts in 4846 days

#1 posted 09-16-2012 11:33 PM

What a buried treasure!! You have created a useful machine out of one that was lost for 9 years! I love it and you will have a machine that you can use forever!!

Thanks for sharing

-- Chuck Emery, Michigan,

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5300 days

#2 posted 09-16-2012 11:50 PM

COOL Sled…

COOL Stop blocks!

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View dustyal's profile


1322 posts in 4723 days

#3 posted 09-16-2012 11:51 PM

I gotta get out to your shop… what other buried treasures have you? Nice job on this sled.

I just updated my sled and added the T track and stops… but my stops are not hinged… and that causes a problem. It wouldn’t take much to change them—whenever I get around to it.

I still don’t understand why my pieces of Phenolic Plywood bowed on me… anyway, I covered my back fence with PSA sandpaper to help hold my project piece in place since mine has melamine.

-- Al H. - small shop, small projects...

View Bob Kollman's profile

Bob Kollman

1798 posts in 4439 days

#4 posted 09-16-2012 11:53 PM

Nice set up Karson, also like the wood hinge set up for the stop.

-- Bob Kenosha Wi.

View SPalm's profile


5338 posts in 5130 days

#5 posted 09-17-2012 12:07 AM

Nice work Karson.
Cool looking boxes too.


-- -- I'm no rocket surgeon

View Roger's profile


21055 posts in 4052 days

#6 posted 09-17-2012 12:19 AM

Way awesome Karson! I really like the whole thing. The wood-hinge stop blocks are a very kool idea. My guess is that you will use this as a dedicated miter cut sled. It’s an awesome build. I know this will last a long long while. I have a sled similar to this, but, I put a 1/4” hardboard insert that can be changed out for different blades, dados, etc., just like a zero clearence insert on your tablesaw. OH, and those boxes are freekin awsome! Really, I likes em a whole bunch.

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

View Napaman's profile


5535 posts in 5325 days

#7 posted 09-17-2012 12:33 AM

my mom tells me she took a dog sled to school everyday when she was a kid (alaska)...but it doesnt look like this! Very nice karson! It looks amazing…thanks for the details…

-- Matt--Proud LJ since 2007

View Karson's profile


35278 posts in 5648 days

#8 posted 09-17-2012 12:35 AM

Thanks guys. The slider does what I wanted it to do. Now I’ve got to find a place to hide it out of the way. Maybe I need a rope to the ceiling.

All of those boxes went away to the children as Christmas Presents. I didn’t make one for my wife so I had to make it after the first of the year.

Click for details

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View CharlieM1958's profile


16292 posts in 5466 days

#9 posted 09-17-2012 12:35 AM

That jig is a work of art in itself, Karson!

-- Charlie M. "Woodworking - patience = firewood"

View blackcherry's profile


3349 posts in 5071 days

#10 posted 09-17-2012 01:14 AM

Nice work on your jig as well Karson, I really like the stop you’ve added and the design. Great work on bring the beast back to life, stay safe my friend…Blkcherry

View Karson's profile


35278 posts in 5648 days

#11 posted 09-17-2012 02:15 AM

Napa: I has a dog sled in Canada. A one dog sled and he was a Labrador. I would hook him up to my wagon or toboggan and let him go where he wanted. I hung on for the ride.

It was great when he pulled the toboggan up the hill. I’d disconnect him off and I’d ride down the hill and he’s run along beside barking all the way down. Then back up the hill. What a great dog.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View mmh's profile


3697 posts in 4970 days

#12 posted 09-17-2012 04:53 AM

Very COOL re-vamp! I LOVE the ambrosia maple boxes too!

-- "They who dream by day are cognizant of many things which escape those who dream only by night." ~ Edgar Allan Poe

View Roger Clark aka Rex's profile

Roger Clark aka Rex

6940 posts in 4683 days

#13 posted 09-17-2012 05:15 AM

Another nice jig Karson. Boxes look great. You clever old fart.

-- Roger-R, Republic of Texas. "Always look on the Bright Side of Life" - An eyeball to eyeball confrontation with a blind person is as complete waste of Time.

View Lee A. Jesberger's profile

Lee A. Jesberger

6875 posts in 5227 days

#14 posted 09-17-2012 11:27 AM

Real nice, my friend.


-- by Lee A. Jesberger

View lew's profile


13430 posts in 5003 days

#15 posted 09-17-2012 02:51 PM

Great looking sled and recovery on the saw, Karson!

I wonder what other fantastic finds were uncovered during this project?!

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

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