Table Saw Sled (w/ Toggle Clamps)




Introduction: Table Saw Sled (w/ Toggle Clamps)

About: We are Mike and Lauren. We make videos on YouTube about money, travel, homesteading, and DIY.

I had kickback accident in the shop (linked in the video above), so I decided to build a cross cut sled to make safer more precise cross cuts on the table saw. I wanted to make it my own so I used UHMW plastic for the runners, and added mini t-track on the back fence for toggle clamps and a flip stop block.

Step 1: Materials

I used UHMW plastic runners from peachtree woodworking that measured 3/4" by 3/8" by 48". I got the 1/4" mini t-track from amazon. It's the shop fox brand. It accepts any 1/4" bolt head, which is nice for making your own accessories. The most expensive part were the Bessey toggle clamps which I modified to slip into the track.

Step 2: Runners

I used screws every 2 inches to attach my UHMW plastic runners to the base of the table saw sled. I predrilled from the top, and used a screwdriver to tighten them.

Step 3: Rear Fence

I made a 3/4" dado in the back fence to fit the t-track. Then I used a countersinking bit to drill holes in the aluminum to screw it into place.

Step 4: Modify Clamps

I used 1/2" UHMW plastic scraps and a 1/4" t-nut insert to make my own t-track mounts for the Bessey toggle clamps. I also had to extend the clamps themselves so they would reach the base of the fence. Since they were an unusual thread (M8 1.25), I had to re-tap an off the shelf 5/16" barrel to join the two.

Step 5: Finished Product

The finished products works great. I spray lacquered the top and bottom and waxed the bottom so it slides easier. The clamps are auto adjusting so they accept any material between 1/2 and 2 1/4 inches!

Step 6: Flip Stop

I also ordered an $8 dollar flip stop block that slides into the t-track as well for easy repeatable cuts.

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    7 years ago on Introduction

    Nice Job! I have to make a sled myself and your design looks very nice.

    wow! I was working on something similar, but more for holding 3d prints, giving me hope and ideas. Awesome job


    7 years ago on Introduction

    awesome! I just subscribed you on youtube! those are great woodworking videos!


    7 years ago

    nice work! while bessey makes some good toggle clamps, you should also check out harbor "fright", they have several very inexpensive ones good for shop fixtures


    7 years ago on Introduction

    Very nice!

    This looks like a mega-ultra-deluxe table saw sled . . . I might be due for an upgrade. Great ideas!