Table Saw Sled Makeover

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Project by MT_Stringer posted 01-10-2014 11:00 PM 12152 views 54 times favorited 16 comments Add to Favorites Watch

I am in the planning stage to build new cabinets for our kitchen. I decided to modify my sled so this would be an easier task.

  • I wanted to be able to cross cut the dadoes for the upper cabinet sides (top and bottom) so an adjustable width zero clearance TS sled seemed like a good idea and a lot faster than using a router and a jig (which I have).
  • I wanted to add the Kreg precision measuring system to the fence and it’s extension.

So, I dismantled my original sled. I used the original fence and cut it to fit as the rear fence. Then I made a new fence out of 3/4 poplar and installed the track.

To make the sled a zero clearance and dado acceptable I made adjusters and attached them to the right side of the base. Slots and my home made knobs allow the base to be adjusted accordingly.

I used the base and one of the original alum bars. The sled was cutting great to begin with so I didn’t see any reason the not use it.

Next I made the extension for the left side. The plan called for a 24 inch fence, but I ran out of real estate. There is not enough room for my belly to clear between the extension and the router table. :-( So, I cut it a little shorter. I feel a lot safer now. I can pass back and forth and not tear the whole thing down.

BTW, I used the plans published by Woodsmith magazine. It is called the Precision Cross Cut Sled. Google it and you should find it.

Here are the pics. I have already posted the pics of the knobs so I won’t get into that again…even though they are working great.

Note: I couldn’t find the Kreg ruler at the Rockler store so I bought their brand which is yellow. Actually I think this will work out well because now I know when I am on the right side of the blade because that ruler is white (left over from the miter saw station). Both rulers index off the left side of the blade. That way I will always know to do my set up calculations based on that fact.

Hope you like it and get some inspiration.

-- Handcrafted by Mike Henderson - Channelview, Texas

16 comments so far

View HuckD's profile


312 posts in 2628 days

#1 posted 01-10-2014 11:12 PM

Some nice ideas there. Thanks for sharing. Favorited.

-- Visit my Youtube Channel:

View Garry's profile


103 posts in 2630 days

#2 posted 01-10-2014 11:33 PM

Very nice!

-- Garry, North Carolina woodworker and engineer - The journey you're preparing for has already begun.

View EJL's profile


1 post in 2511 days

#3 posted 01-11-2014 12:44 AM

Nice project. I have wanted to build a sled to use with my dado blade… Excellent and simple solution.


-- Ed, Kingwood, TX

View Northwest29's profile


1704 posts in 3405 days

#4 posted 01-11-2014 12:54 AM

Very cool modifications. I have to make some changes to mine as well.

-- Ron, "Curiosity is a terrible thing to waste."

View jeff's profile


1261 posts in 4379 days

#5 posted 01-11-2014 01:04 AM

nice sled-definitely will be handy for your future kitchen cabinet build…

-- Jeff,Tucson,Az.

View Glen Peterson's profile

Glen Peterson

556 posts in 3970 days

#6 posted 01-11-2014 03:18 AM

Looks solid. I remember seeing the sled in Woodsmith. Is it wide enough, 24” +, to cut the lower cab parts to length as well? I’ve built cabinets in 2 kitchens and then sold the houses. I hope you’ll be able to stay and enjoy your work for many years.

-- Glen

View MT_Stringer's profile


3183 posts in 4145 days

#7 posted 01-11-2014 03:54 AM

@Glen, no it is not. I have about 20 inches in between the fences. The last cabinets I built, I used the fence on the saw as the guide for cutting, and for the dadoes (one on top, one near the bottom, and the back),

With that said, I don’t see why you couldn’t make a larger one. I am really limited on space plus I wanted to reuse the material I already had.

Note: Our house is paid for. I hope we stay here for a long time also. I only want to do this once. :-)

-- Handcrafted by Mike Henderson - Channelview, Texas

View bushmaster's profile


3980 posts in 3197 days

#8 posted 01-11-2014 11:23 PM

This about the best idea of the table saw sled I have seen. Thanks for the pictures. My mind is starting to turn and soon saw dust will fly.

-- Brian - Hazelton, British Columbia

View MT_Stringer's profile


3183 posts in 4145 days

#9 posted 01-11-2014 11:26 PM

Thanks Brian. Google up the plans and gitafterit! :-)

-- Handcrafted by Mike Henderson - Channelview, Texas

View scarpenter002's profile


618 posts in 4819 days

#10 posted 01-12-2014 12:07 AM

Nice addition for your shop Mike. That is a nice looking sled. I have been looking a design in ShopNotes that also utilizes the Kreg Top-Track and Flip-Stops.

Thanks for sharing.

-- Scott in Texas

View JerrySats's profile


237 posts in 4524 days

#11 posted 01-12-2014 01:54 AM

Great job on the CC Sled , I like the design . I need to build a new sled and think this will fit the bill nicely . Thanks

View jimmy meeker's profile

jimmy meeker

135 posts in 2910 days

#12 posted 01-24-2014 02:18 AM

kind like something i built but yours is lighter then mine . and i think a little nicer. mine is a little heavier built i seen a couple ideas after i already started on mine. nice job you must have a little more Experience then me. i am still learning but getting better

-- jrm123

View ChipOffTheOldBlock's profile


65 posts in 2653 days

#13 posted 03-31-2014 02:54 AM

Very well done. I’m almost finished my own after seeing the design with Woodsmith. However, I’m not sure about the rear fence design. The plans suggest to use one 3/4 piece instead of a 1.5 to 2 inch glue-up.

-- "Excellence is a thousand things done just a little bit better"

View MT_Stringer's profile


3183 posts in 4145 days

#14 posted 04-03-2014 07:45 PM

I used the sled to cut some dadoes in the sides of some drawers I built. They are going into a wet bar and the homeowner likes to be organized. With some simple dividers made out of 1/4 inch drawer bottom material, she can use the dividers as needed or remove them. I think she will have fun.

To cut the dadoes, I set up my sled with just the two dado blades. I adjusted the sled to give me near zero clearance when making the cross cuts.

The drawer sides are almost 22 inches long so I set a stop at about 7 1/2 inches. I forgot exactly what measurement I used.

I made all of the cuts on one end of each board, then I flipped them around and made the cuts again. Dang that was easy. Eight drawers with the dadoes cut in no time at all.

This was the plan from the beginning of the sled makeover and it worked great.

Hope you find this info useful.

-- Handcrafted by Mike Henderson - Channelview, Texas

View MT_Stringer's profile


3183 posts in 4145 days

#15 posted 04-18-2014 05:22 PM

Another good day using the sled.

I was preparing some wall cabinet pieces. I set up two stop blocks. The one on the left positioned the board so I could cut the dado flush with the top of the workpiece. The second stop was set to the right so I could cut the dado for the cabinet bottom to fit into the end. Cranked up the saw and went to work. That made short work out of cutting the dadoes.

Note: I had previously tested the dado stack and discovered for the plywood I was cutting, I needed the two outer blades and four 1/8th inch cutters plus a shim. I have those marked and a handwritten note to remind me in case I have to cut anymore with that same plywood.

-- Handcrafted by Mike Henderson - Channelview, Texas

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