Sled Runners

[jackellis]

After four attempts, I've about given up on wooden runners for table saw sleds. Three were too sloppy and now one is too tight because the wood moved. My "good" sled cuts accurately enough but it's not wide enough and over the last few months, the oak runner has apparently warped enough that it takes quite a bit of force to move the sled across the table, which is getting to be unsafe.

I need to cut a bunch of panels for cabinets and I'm planning on making the Ultimate Crosscut Sled in FWW #199. This will be a large sled capable of cutting full width sheets of plywood so I don't have to make another one ever again.

At this point the question is whether to use aluminum or steel bar stock for the single runner. The tolerances on steel stock seem to be tighter but steel is quite a bit heavier and a bit more expensive than aluminum.

Any suggestions?

[shoottx]

Jack

I just finished reading this post from FWW, http://finewoodworking.taunton.com/i...tablesaw-sleds about making the sleds. It may answer some of your questions!

[atgcpaul]

At this point the question is whether to use aluminum or steel bar stock for the single runner. The tolerances on steel stock seem to be tighter but steel is quite a bit heavier and a bit more expensive than aluminum.

Any suggestions?

I used 3/4" aluminum T-track for my panel sled runner. Works well.

http://www.bt3central.com/showthread...highlight=sled

I'll probably go this route again when I make my cutoff sled (someday).


Paul

[cgallery]

Here is my thread on how I used UHMW runners. Still working superbly. Have two sleds using the stuff and have been through a few seasonal adjustments and no change in fit.

http://www.bt3central.com/showthread.php?t=37996

[RodKirby]

3/4 x 3/8 UHMWPE Sled runners -

Drilled/tapped to attach with 1/4-20 screws (counterbored).

Sideways drilled/tapped for 1/4-20 nylon tipped steel set screws

EASY to adjust - work perfectly

[jackellis]

I have a block of UHMW but I'm not sure how to cut it so there's a smooth surface on both sides. TS, or BS?

[pelligrini]

I really like using the Incra miter sliders. http://www.woodcraft.com/family.aspx...s=5121&pcs=fam They are adjustable, and not very expensive.

[drumpriest]

I used a couple of sets of these, are on sale for 9$ a pair. I do worry about whether or not they could/will damage the miter slots though.

http://www.rockler.com/product.cfm?p...r&cookietest=1

[cgallery]

I have a block of UHMW but I'm not sure how to cut it so there's a smooth surface on both sides. TS, or BS?

I'd do table saw with a carbide-tipped blade.

[poolhound]

Jack,

I guess I must just have been lucky. I have 3 sleds all using wooden runners, 2 with oak and one with walnut. at 3/4" wide there shouldnt really be that much expansion and contraction but I guess it depends on where you live and the realtive humidity levels. Maybe living in PHX I am luckier than most. This winter they did get a little on the tight side but nothing too bad. The oldest set has been will have been in use for 2 years this summer. I guess I should wait and see what happens this year when the temp gets to 110 with <10% humidity.

Another issue is wether (and how) they are finsihed and how they are attached. After cutting and fitting for size I usually treat mine with a couple of coats of wipe on and then keep them waxed. I attach them to the sleds with a screw approx every 5". This shouldnt give them much of an opportunity to warp.

[jackellis]

Thanks for all the great suggestions. I have several 4' sections of Rockler T-track but I hate to use them for something like this. Aluminum bar stock runs about $5 for a 4' section...plus $13 for shipping - have to check out the Borg. I think my block of UHMW is 4' long.

I guess the key thing on this attempt is to screw the runner in place only. No glue.

[ehamady]

I'm a new member and this may be a little late, but I use my router to create a shallow channel for the runner. It keeps the runner staright and sliding smooth.