Panel Cutoff Sled Finished

[bmuir]

Wanted to build a panel cutoff sled. Searched the Internet, but found this one in an old issue of Popular Woodworking (2002). It is 20"x24" and made from MDF. It uses a 1-1/2 x 1-1/2 aluminum fence held to the base by 1/4" socket head cap crews, plastic washers, and t-nuts. To this Al fence, you screw a replaceable, 1-1/2" x 3/4" plywood fence with 120 grit sandpaper glued on the face (this wooden fence can be replaced and gives you a fresh zero reference point if thing change). Cap screws are in slightly oversized holes to allow the fence to wiggle a bit when squaring up to the right side of the sled which was cut off by the blade. Miter slot runner is UHMW plastic. Lots of screws used so you can tighten the screws a bit to get the plastic to expand a little giving you a zero-clearance fit in the miter slot (works!).

Sled cut right angles dead on after the initial adjustment. Could not be happier.

Note: If you were to cut a panel in half, you would want to clamp a scrap piece of 3/4" MDF on the right-hand side of the saw table to keep the scrap piece from falling off and possibly kicking back.

Bill

http://i178.photobucket.com/albums/w...utoffsled1.jpg
http://i178.photobucket.com/albums/w...utoffsled2.jpg
http://i178.photobucket.com/albums/w...utoffsled3.jpg

[cgallery]

Pretty slick. I posted a thread on the Incra Positioner yesterday that had my sled w/ an aluminum fence. It uses a base that has two t-slots, and a wooden sub-fence with two t-slots. It allows me to make perfect adjustments for 90-degrees. However, I can also go to 45-degrees or whatever angle I like. Fast and easy to adjust, too.

[ejs1097]

Well thought out with the replaceable fence. Looks simple enough as well.

I've been kicking around a sled myself, I think I found a winner.

Did you make the runner or purchase?

[bmuir]

Well thought out with the replaceable fence. Looks simple enough as well.

I've been kicking around a sled myself, I think I found a winner.

Did you make the runner or purchase?

Cut the runner from 3/8-inch UHMW plastic stock.

[Ed62]

That looks like a simple solution. Nice job.

Ed

[bigstick509]

Very Nice

[Tom H]

Bill,

Looks like you did a really good job on that.

Now....forgive my newbie(ness).

What is it used for?

Thanks

Tom

[mater]

That is very nice. I need to build one myself.

[lrogers]

Pretty slick!

[ejs1097]

Bill,

Looks like you did a really good job on that.

Now....forgive my newbie(ness).

What is it used for?

Thanks

Tom

Well, it's to cut a panel. Such as large, wider pieces that would require moving the fence too far to the right for example. It also is a great way to square up panels knowing the sled's fence is square to the blade (mitre slot pararell to the blade).

typically, you'd cut down playwood or glued up solidwood slightly larger then finished size. Then mark the panel for exact measurement. Since the fence is zero clearance, you place your line directly at the fence's cutoff point and push it through for accurate cuts.

An example is cross cutting glued up panels where both ends are uneven. Using the sled will make a 90 degree cross cut off a flat edge.

[John Hunter]

Very nice.

[Tom H]

Ah ha! Thanks. Looks very handy.

Tom