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How to Make a Table Saw Sled

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If you are looking to improve the versatility and function of your table saw, a table saw sled can allow you to make cross cuts or 45-degree angle cuts with incredible accuracy. A table saw sled works to hold your wood piece in place as you cut, offering you a durable guide as well as enhanced safety protection.

Learning how to make a table saw sled is relatively simple if you follow these step-by-step instructions.

​How To Make a Table Saw Sled

​If you’re just getting started as a DIY hobbyist, chances are you don’t have the most expensive of table saws. A table saw sled can help you overcome some of the deficiencies of an inexpensive table saw. A sled will give you more versatility, while also increasing your accuracy. Here are step-by-step instructions for you to follow:

1. Gather the Supplies You Need

To begin the process of how to build a table saw sled, you first need to gather all the tools and materials you need to complete the project. This is a complete list of everything you will need for the cutting, assembly, and building of your table saw sled:

how to make a table saw sled
Photo credit: Mitch Barrie on Flickr / CC BY

2. Cut Plywood for the Base

The first step is to cut a piece of plywood that is roughly 2/3 the depth of your table saw table and 2 to 3 feet wide.

This will act as your base for your table saw sled and the rest of the pieces you cut and construct will attach to this base.

3. Cut Runners for the Guides

You now need to cut two runners to attach to your table saw sled and slide through the miter gauge slots.

It is best if you cut two runners for your table saw sled as one runner will not provide you as much support as you might need.

Your miter gauge slots may not be identical in nature. Take your time to cut each runner’s width and length, so it fits accordingly. The width has to be exact to allow the runner to slide along the slot with play left to right. The length should equal the depth of your sled base.

4. Assemble Runners to the Base

To attach your runners to your sled base, you will need place each runner in each miter gauge slot.

Place your sled base on top and mark where you need to place your screws to hold the runners securely. Your runners should be able to slide in the miter gauge slots with ease and be flush with your tabletop.

Use your drill with a countersink bit to drill holes where you need to place your wood screws. Five holes for each runner should be enough and provide a secure hold.

After the runners have been attached to the table saw sled base, check how it slides through the miter gauge slots. It should move freely without any friction. If friction does occur; you may need to adjust the width of the runners.

5. Build and Mount the Fence

Next, you will need to cut a fence piece from your plywood that will act as the stopping block for your wood piece when cutting.

It should be the width of your table saw sled and 2 to 3 inches thick. Attattach at one end to help you move the wood piece through the saw blade.

Attach the fence using your clamps to hold it in place while you drill holes for your wood screws.

6. Make a Kerf Cut in the Base

You will also want to make a kerf cut along the full base of your table saw sled. This will allow the saw blade to run through the sled without obstruction or limitations.

You will want to make sure your fence and kerf cut are calibrated and can use your framing square to test for straightness of the fence and cut.

Adjust both as necessary to create an accurate straight edge by using your shims to take up any slack or gaps that have occurred.

You may also want to add a few support blocks to your fence as this does most of the pushing and pulling into the saw blade and can become loose over time.

7. Test and Begin Cutting

Place your table saw sled on your table saw and use your fence to push a piece of wood into the blade.

It should slide easily into the miter gauge slots and provide you plenty of guidance as you cut with the saw. It should cut with ease and provide no issues as you cut.

Conclusion

You have successfully completed your table saw sled with this simple how to make a table saw sled guide. You can begin enjoying your new table saw sled and make more accurate cuts without the worry about kickbacks or wood strikes. It is the ideal accessory for your tabletop saw and will get plenty of use for your woodworking projects.