Kirby’s Shed: 9a. TS Xcut sled

[RodKirby]

Mainly for my Darkside friends:

This started out to be a "trial" sled. I wasn't sure what I wanted/needed on my new TS. After 18 months, it has done all I've needed, so it stays as is

I seem to cut a lot of "smaller" stuff, and I find it difficult to exactly align a pencil mark to the blade - can't get over the top to see.

With the sled, I just move it towards me and align to the saw kerf

Note travel stop.



Guard is 1/4" Lexan



Support for the longer stuff:



Length stops - for either side of the blade



Two UHMWPE runners - 1/4-20 set screws for alignment

[jgrobler]

Looks very nice. No MDF? I like the "cover" in front so the blade stays under cover when the front fence passes over the blade. ummm, one day I'll also have one, until then my BT3 SMT will suffice.

[cgallery]

Hey Rod, that looks nice.

Can you elaborate on how you attach the runners to the sled? And how you use the grubscrews for alignment?

[p8ntblr]

Nice sled. Did you use plans or is that a RodKirby original?

[RodKirby]

cgallery: I drilled/tapped 1/4-20 holes in the UHMWPE and used panhead bolts (you can see the counterbores in the top 2 pics).

The set screws allow me to make sure the runners are "snug" in the miter slots - no sideways movement.

p8ntblr: Kirby original (after looking at a whole lot of books/magazines etc.).

[jussi]

Since you made it Rod I'm sure it's perfectly square. Any advice for someone building their first sled on how to assure squareness? Also I'm not too familiar with grub screws. Why did you use those?

[RodKirby]

Since you made it Rod I'm sure it's perfectly square. Any advice for someone building their first sled on how to assure squareness? Also I'm not too familiar with grub screws. Why did you use those?

Ensuring squareness: (This how I did it)
-Make up the base (with runners), and short fence (glued and screwed). This one doesn't have to be "spot on" square.
-Predrill the base for screws for the long fence.
-Set your saw blade height so it won't cut right thru the short fence.
-Start cutting thru the sled and stop about 1/2" from where the long sled will be located. Switch off the saw.
-THIS IS THE CRITICAL PART: Using a "reliable" square (maybe a plastic drafing square), place it against the saw blade body, NOT against the teeth. Apply glue to the long fence and place it on the base, aligning it with the square - flip the square to the other side of the blade to make sure you have aligned it properly. Place weights (see second pic as an example) on the long fence - check alignment AGAIN and AGAIN! The weights will make the fence move until the glue "grabs".
-Walk away - for 24 hours!
-Predrill pilot holes in the long fence and insert screws.
-Check saw height! Place the sled on the saw table and complete the cut


Grubscrews (Oz) = Set screws (USA) -with a nylon tip, allow you to change the width of the runners so there is no "slop". Note the hex socket in the end.

[MilDoc]

OK Rod, just how much to ship you're whole shop Ito meI?

[jussi]

Thanks Rod. Sounds easy when you explain it.

[LCHIEN]

I get it. Grub screw = aussie slang for Set screw in US lingo.

[RodKirby]

I get it. Grub screw = aussie slang for Set screw in US lingo.

Oops - SO sorry guys. I REALLY try to avoid this kind of problem - I will change the posts...

Thanks, Loring

[p8ntblr]

Anyone know where you can get the UHMWPE runners? I haven't dealt with the material before. How easy is to drill through? Any special bits needed? I'm assuming you used a DP?

[LCHIEN]

Anyone know where you can get the UHMWPE runners? I haven't dealt with the material before. How easy is to drill through? Any special bits needed? I'm assuming you used a DP?

UHMW polyethelene (PE) is widely available. For example:

http://www.rockler.com/product.cfm?p...80&filter=uhmw
has limited sizes in 48" lengths as well as tape and thin sheets.

It's also available in a multitude of sizes and shapes from places like www.USplastics.com

For runners in TS miter slots (usually 3/4" x 3/8"), you can get 4" x 48" x 3/4 or 3/8 material and rip the other dimension.

It's plastic, kind of slick feeling. Machines and cuts very cleanly and easily with woodworking type tools and cutters (e.g. table saw, bandsaw, drillpress). When cutting with table saw be careful and consider dust collection, because you'll get a snowstorm of white shavings.
hand drill will work of course but hard to get perfectly vertical/square drilling by hand.

[RodKirby]

Or, if you're in Oz...

http://www.woodworksupplies.com.au/prod39.htm

3/4" x 3/8" x 24"

[Knottscott]

Rod, you could make a gourmet dinner out of peanut butter and jelly sandwiches!