103 - Table Saw Panel Sled.pdf

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Table Saw
Panel Sled
© 2007 August Home Publishing Co.
F
ixtures
J
igs
&
t
able
s
aw
P
anel
s
led
!/4"
Slot
Runner
Adjustable
stop block
!/4"
Spacer
Panel
Sawdust relief
!/4"
Counterbore for
carriage bolt
!/4"
Space
between
fences
T
his panel sled is both simple
to build and very practical. It
was orginally designed for trim-
ming the ends of large glued-up
panels. But I found that by adding
a stop block, it could also be used
as a cut-off jig for cutting several
pieces to equal length.
BASE.
To make the sled’s base,
cut a piece of
3
/
4
"
plywood 16" wide
and long enough to extend 12"
past the wing of your table saw.
RUNNER.
The base is guided by
a 19"-long runner that fits in the
left hand miter gauge slot on the
table saw. I made the runner from
maple, but you could use plastic or
metal, or a store-bought runner.
The important thing is that the
runner fits the slot without any
play, but still slides smoothly.
After the runner is cut to fit the
slot, drill four countersunk screw
holes in it from the bottom.
Now, put a couple of pennies as
spacers in the slot, set the runner
on top of them, and apply double-
sided carpet tape to the top of
the runner. Then, place the ply-
wood base on top of the runner
with the right end of
the base about 1" to
the right of the blade.
(Tip: To keep the base
square with the blade, I placed
my rip fence 1" to the right of the
blade as a stop.) The extra 1" will
be trimmed off later.
After pressing down firmly
so the carpet tape sticks to the
bottom of the plywood base, lift
up the assembly, flip it over, and
screw the runner in place.
REfERENcE EdgE.
Next, place the
sled back into the miter gauge
slot and trim off the extra 1". This
end of the sled now will act as a
reference edge. As long as you
use the same saw blade, you can
be assured that the cut will align
with this edge.
fENcE.
The next step is to add a
fence to the trailing edge of the
base. The fence is made from
two strips of
3
/
4
"
-thick stock sepa-
rated by a couple of small square
spacers made from
1
/
4
"
plywood.
The spacers allow a slot for a car-
riage bolt that holds a wooden
stop block to the fence.
Sawdust
relief
Plywood
base
Once the fence is glued
together, use a framing square
to position the fence square with
the reference edge (and the saw
blade). Then screw it in place
from the bottom. (Note: Don’t
glue it so you can come back later
and adjust it if necessary.)
Stop Block.
The stop block is
made from a small piece of
3
/
4
"
-
thick hardwood, a
1
/
4
"
carriage
bolt, a washer, and a knob (or
wing nut), see inset drawing.
USINg tHE SlEd.
When cutting mul-
tiple pieces to the same length, I
use a three-cut procedure. First,
cut all of the pieces to rough
length. Then cut a clean end on
one end of each piece.
Next, tighten down the stop
block so the distance from the
block to the reference edge
equals the desired length. Finally,
position the clean end of each
piece against the stop block and
cut it to final length.
1
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© 2007 August Home Publishing Co. All Rights Reserved.

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