Intro: Table Saw Sled (w/ Toggle Clamps)
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.