All seasons cross-cut sled for TS

[niki]

Good day

Today, I was working on the router table fence, the "Fence/Bit" precision distance system and the "Fence stops" precision positioning system.

I took some 3 Tons of pics but I have to "Delete", "Sharpen", "Add Text" etc and it will take some time to post.

In between, I needed a sled to cut small (and not so small) pieces so I made one in 15~20 minutes from the "Floor Panels" left-over that I used for the router table.

I called it "All seasons sled" because temp and humidity changes are not effecting the sled runners that usually are expanding and contracting with humidity changes.

The sled is always tight, without any "Side play" and can be "re-adjusted" in seconds.

Because of the construction method, everything is very square to the blade and no need of "Two cut test" or "Five cut test"...it's dead 90°...as long as the blade is parallel to the miter slot and your triangle is accurate...

And last, it's sliding, actually half rolling, and is very, very easy to push-pull.

Many variations can be done on this sled and I leave it to your imagination (I have a few ideas).

Sorry but I did not take any pics of the WIP so if you have any questions, I'm here...

Regards
niki

[cgallery]

Quite ingenious!

[final_t]

I still love that roller idea from this and the M&T unit. Very very clever!

[ragswl4]

Niki,

Another great idea. What kind of flooring material are you using for the base? Thickness, what material it is made of? I think it has an MDF substrate but wanted to know for sure. I see you use this material quite often and apparently it is very stable and I would like to see if I can obtain it. Thanks and if you don't mind, I'd like to copy and make one of those sleds as I need one for my TS.

[siliconbauhaus]

Brilliant! More details please mate.

You should post that router table here as well

[lcm1947]

Another good idea Niki. Due to my TS setup I do need a sled like that and have been sort of looking around for one to build. Yours looks simple and quick to build. I may have to copy it myself and I assume you'd have no objections since you posted it. If so you better hurry and stop me as I will probably knock one out this weekend. Thanks again Niki.

[radhak]

Having built a sled myself using two miter-slots, I feel the biggest challange is getting the fence on the sled to be exactly 90° to the blade - something i have not full confidence in. Could you help in detailing what's the best/easiest way of doing that?

(in other words, i cut the sled the first time; now i put a triangle against the blade, and use it's other side to align the fence. but how do i fix this fence accurately to the sled - maybe apply glue and hold the fence onto the sled with the triangle as support...?)

[niki]

Thank you for your kind words

As you can see, I posted it around midnight - Poland time.
Now it's 7:30 AM here (good morning)

So, please don't do nothing...I will make another one today and take "step-by-step" pics and post it as "All season crosscut sled WIP".

There are 2 "secrets" in building this sled;

1. The runner is cut to 1/32~1/16" narrower than the miter slot and that makes the runner preparation "piece of cake".

2. I'm not using the "Static position" of the blade to square the fence, but instead, the "Dynamic position" of the blade that can be a little bit different from the "Static position" due to "external forces" like play in the arbor, up-down system or any other moving part that changes position during the blade rotation.

So, get ready your "Floor panels"....(you can use other materials as well, I used 5/16" floor panel because I have left-overs)...And your accurate Plastic triangle

Regswi4
The floor panels are 5/16" thick, made of HDF (High Density Fiberboard) and are covered with Plastic laminate (Formica) on both sides that makes them very strong (10~25 years guaranty), very stable and very slippery (just Google "floor panels).

Siliconebauhaus
Mate, the router table is posted, "New router - New table"

Thanks again and see you tonight (my night -your noon)
niki

[Uncle Cracker]

I feel the biggest challange is getting the fence on the sled to be exactly 90° to the blade - something i have not full confidence in. Could you help in detailing what's the best/easiest way of doing that?

I'd suggest using an aluminum extrusion for the "fixed" fence, and a permanent fixture, such as a pivot pin, on one end, and a slotted fixture at the other end, so that the fence can be adjusted for square. Then, check for square against a crosscut piece of scrap, rather than against the static blade. This will allow for any deviations arising from blade drift or "play" in the sled.