If you’re an avid woodworker, you know how important it is to have accurate and reliable tools. When it comes to using a table saw, one essential accessory you should consider is a sled. A table saw sled can help you make clean and precise cuts, especially when working with larger pieces of wood or when making repetitive cuts.
A crucial component of a table saw sled is its runners. These are the strips of wood that fit into the miter slots and allow the sled to slide smoothly across the table saw surface. In this article, we’ll guide you through the steps to make your own table saw sled runners, ensuring a perfect fit for your sled and improving the overall performance of your woodworking projects.
Materials Needed:
- Hardwood stock (such as oak or maple) – 3/4″ thick
- Table saw
- Measuring tape
- Saw
- Router or sandpaper
- Pencil
- Disposable gloves
- Safety glasses
Before you begin, make sure that your table saw is clean and free from any debris or sawdust. This will ensure accurate measurements and a smooth fit for your sled runners. Also, don’t forget to wear your safety glasses and disposable gloves to protect yourself during the process.
Step-by-Step Guide to Making Table Saw Sled Runners
Table saw sled runners are an essential accessory for any woodworking enthusiast. They help to ensure accurate and safe cuts when using a table saw sled. Follow these easy steps to make your own table saw sled runners:
Step 1: Gathering the Materials
Before you start making the runners, gather all the necessary materials. You will need:
- Hardwood or UHMW plastic sheets
- Measuring tape or ruler
- Pencil or marker
- Coping saw or jigsaw
- Sandpaper
- Drill with a drill bit
- Screws
Step 2: Measuring and Marking
Take the measurement of your table saw’s original runners using a measuring tape or ruler. Transfer the measurements onto the hardwood or UHMW plastic sheets and mark them with a pencil or marker.
Step 3: Cutting the Runners
Using a coping saw or jigsaw, carefully cut along the marked lines to create the runners. Take your time and ensure the cuts are precise and straight.
Step 4: Sanding the Runners
After cutting the runners, use sandpaper to smooth the edges and surfaces. This will remove any rough edges and ensure a snug fit on the table saw sled.
Step 5: Drilling Holes
Measure and mark the positions for the holes on the runners. Use a drill with a drill bit to create the holes. The holes will be used to attach the runners to the table saw sled.
Step 6: Attaching the Runners
Place the runners on the bottom surface of the table saw sled and align them with the edge. Use screws to attach the runners securely to the sled. Make sure the screws are tight but not over-tightened, as this may cause the runners to crack or split.
Step 7: Testing and Adjusting
Once the runners are attached, test the table saw sled by sliding it back and forth on the table saw. Make any necessary adjustments to ensure smooth and accurate movement.
With these simple steps, you can make your own table saw sled runners and improve the safety and precision of your woodworking projects. Remember to always use caution when working with power tools and follow proper safety guidelines.
Choose the Right Materials
When making table saw sled runners, it is crucial to use the right materials to ensure their durability and performance. The materials you choose should be sturdy enough to withstand the pressure and friction generated by the table saw’s blade.
One popular material choice for sled runners is hardwood, such as oak or maple. Hardwoods are known for their strength, stability, and resistance to wear and tear. They provide a solid base for the sled and allow for smooth and accurate cuts.
Another option is plastic, specifically UHMW (Ultra-High-Molecular-Weight) plastic. UHMW plastic is a tough and slick material that offers excellent resistance to abrasion and impact. It is self-lubricating, which reduces friction and allows the sled to glide effortlessly on the table saw’s surface.
When deciding between hardwood and plastic, consider your specific needs and preferences. Hardwood may be a better choice if you prioritize durability and stability, while plastic may be preferable if you value smoothness and ease of use.
| Material | Pros | Cons |
|---|---|---|
| Hardwood | Strength, stability, wear resistance | May require more maintenance |
| UHMW Plastic | Toughness, self-lubricating, low friction | Less traditional, may be less durable |
Whichever material you choose, make sure it is flat, smooth, and properly dimensioned. Inaccuracies or warping can affect the performance of the sled and compromise the accuracy of your cuts.
Remember to measure your table saw’s dimensions and the slots on the table accurately to ensure a snug fit for the sled runners. This will provide stability and prevent any unwanted movement during your woodworking projects.
Measure and Cut the Runners
Before you can make the table saw sled runners, you need to measure and cut the pieces to the appropriate length. The runners will need to fit snugly in the miter slots of your table saw, so precision is key.
Start by measuring the width and depth of the miter slots on your table saw. These measurements will determine the dimensions of your sled runners.
- Use a tape measure to measure the width of the miter slot, from one side to the other. Write down this measurement.
- Next, measure the depth of the miter slot by measuring from the top surface of the table saw to the bottom of the slot. Write down this measurement as well.
Once you have these measurements, you can proceed to cut the sled runners from a suitable material. Popular choices include hardwood, plywood, or even plastic laminate.
Since the runners need to be both straight and smooth, it’s important to take your time and use the appropriate tools for the job. A table saw, miter gauge, or circular saw can all be used to make accurate cuts.
Remember to cut the runners slightly longer than the measurements you took earlier. This will allow you to fine-tune the fit later on by sanding or trimming down the length, if necessary.
Once the runners are cut to size, make sure to remove any rough edges or splinters. Sand them down to ensure a smooth surface that will slide effortlessly in the miter slots.
Attach the Runners to the Sled
Once you have cut the runners to the desired length and width, it’s time to attach them to the sled. Start by marking the position where the runners will be attached on the bottom of the sled. Make sure to measure and mark accurately to ensure a straight and square cut.
Apply a bead of glue along the marked lines on the bottom of the sled, making sure to evenly spread the glue. Press the runners firmly into place, making sure they are flush against the bottom of the sled. Use clamps or weights to hold the runners in place while the glue dries.
For added strength and stability, you may also choose to reinforce the attachment of the runners with screws. Pre-drill holes in the runners, making sure not to go all the way through. Then, drive screws through the pre-drilled holes into the bottom of the sled, securing the runners in place.
Once the glue has fully dried and the runners are securely attached to the sled, you can test the sled on your table saw. Make any necessary adjustments to ensure a smooth and accurate glide along the saw’s surface.
Remember, the runners should fit snugly in the table saw’s miter slots, but still allow for easy movement. If the sled feels too tight or too loose, you may need to make further adjustments to the runners or the miter slots to achieve the desired fit.
Tip: Applying a coat of wax or a lubricant such as silicone spray to the runners can help reduce friction and improve the sled’s performance.
By following these steps, you can successfully attach the runners to your table saw sled, creating a reliable and accurate sled for your woodworking projects.
