Intro: Harbor Freight Mighty Mite Saw Sled
First make sure you are wearing your safety glasses. We will be using super glue and cutting the tray which will make sum nice nasty stuff for your eyes.
I found this saw and like all Harbor Freight tools it needed some tweaking to make it right. I needed a sled for small cuts so it was time to down size a normal table saw sled as well as a few other mods.
The inspiration for this mod was because this little saw near chopped off my middle finger and went deep enough to break bone. I would post the photos of the carnage but in the interest of good taste I will not.
Step 1: Make a Proper Base
Once of the serious design flaws of this saw is that it is top heavy. If used the way it is it will easily tip over (shaking my head). The table is large in comparison to the base. Just plain upside down.
I fastened it to a plank of wood that was 16" x 12" (scrap wood that just happened to be that size). To transfer the spacing of the mount I used a piece of card stock paper. Once transferred I drilled the holes so that the heads would be recessed. I used the rubber feet that it came with to reduce vibrations.
I then used two cable tie anchors to manage the cord.
Step 2: The Dimensions and Final Assembly
I used a wooden tray I got at Micheal's. It was $4 if I remember right. It is an item that is not shown online. Check the pics and you will see the dimensions.
The tray is pine ( I think) and the slides as basswood.
The only dimensions that are crucial are the dimensions between the slides. Otherwise it is totally free form.
When installing the slides they must be square to the tray.
Raise the table until it is above the saw blade.
I used slow setting super glue for this part. Once I had the slides shaped to the proper dimensions width wise I set both slides in the slide slot. Applied super glue to one slide (don't be sloppy here - Be stingy with the glue as you are just making a temporary set up) and then set the tray on the table and lined it up with the back edge of the table. Once it was set in place I gave it a few minutes to set up and then lifted it up and then I glued the other slide the same way. BUT first check to make sure the slide is square at this point before proceeding. See why I said be stingy with the glue.
Now with the table in the up position make sure the sled slides easily on the table. if it binds shape the slides so they moves easily through the slots. After you have it fitted like it should be apply more glue along the sides of the slides. Once the slides have dried remove excess glue. Then I used a thumb plane to shave the slides until they allowed the sled base to contact the table.
After the slides were on the tray I lowered the table in increments to make the blade slot. The temptation is to lower it to the final cut and just shove it through. I can say from experience that this saw just does not have the power to do such a cut.
Be careful how deep you make this cut as you can easily compromise the front and rear sides of the sled. As you can see in my photos I added a small bit of wood to reinforce the sides.
Use caution when using this saw! Don't let it's diminutive size fool you. It can do incredible amounts of damage in the blink of an eye.