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
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
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