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My old sled was mortising vs straight router bit note best thing I ever built for my shop, but there was one big problem with it… it was too big! So I decided to create a smaller sled that has the ability to turn into a larger sled with an extension wing. While I was at it, I decided to add a few more features, the ability to cut 45 degree bevels and an adjustable fence to cut any angle you need! First, I ripped the plywood into strips to create the fences. I cut these wider than the final desired dimension so they can be trimmed to size after glue up.
Then I glued the strips using a level to make sure the fences will stay really straight and flat. Next I shaped the base, this takes out some of the weight to make it lighter. This was my first time using a track saw and it totally lives up to the hype. My folding router edge guide mortisibg came in handy here! But you can also use a dado stack in your table saw or make multiple passes with a single blade to create the dados.
I cut it to fit mortising vs straight router bit note miter slot mortiskng drilled countersunk holes in it. Used washers to raise it up a bit, then put on double sided mortising vs straight router bit note to temporarily attach it to the base. I used the fence as a reference for where to place the runner on the bottom of the base.
I flipped the base over and locked the runner down with screws. Then cut the t-track to size and installed bote in the dados using 5 minute epoxy and screws. After the glue dried on the fences I trimmed them to final size at the table saw and miter saw.
I cut the t-track to size and then attached it to the fences using screws. Note, to mortising vs straight router bit note it easier to line up the extension mortising vs straight router bit note with the main portion of the sled, I offset the t-track a bit when installing it.
And used a slot cutting bit in my router to create alignment slots for the extension wing. Then cut and shaped some scrap material to size so that they fit in those slots. Kind of like elongated biscuits. I glued my homemade biscuits into the slots only on the extension portion of the base and fence. The bi fence is now aligned Mortising Vs Straight Router Bit Github because of the biscuits but it needs a way mortising vs straight router bit note it to lock in place.
I mortising vs straight router bit note some oak strips and screwed them to the back of the extension fence, making sure there was some overhang on the side. Then I lined up the extension fence with the main fence and clamped a level to both pieces to make sure they were fully parallel to each other.
Next I installed threaded inserts into those holes on nlte fence. I put threaded inserts into both parts, but stacking threaded inserts like this is not really suggested. So when I install the extension wing, I make sure the oak strip is fully flat against the plywood fence before tightening the knob.
Just a few more finishing details before assembling it all! I added a chamfer to the bottom front edge of the fences to catch sawdust and make the cuts more accurate. And used a round over bit on all the edges that will be touched for a better feel.
I started with the back fence. I cut angles on the sides of it just for aesthetics, I thought it looked cooler. Once clamped I flipped the sled over, predrilled holes and locked it down with screws. Then I cut through the sled stopping just shy of the front. The best way to square up mortising vs straight router bit note front fence is to only install one screw on one side of the fence.
Then line up a square to the cut line made in the previous step and pivot the fence until it looks perfectly square. Once the fence looks like it is square to the kerf cut in the bottom of npte base, lock down the other side of the fence. Make a few more tests cuts to make sure the fence is actually square, then add more screws all along the fence to lock it down further.
Git that I know the main fence is square to the blade I can set the extension fence for square. I locked the extension fence in mortisign using the mortising vs straight router bit note inserts and knobs. Then I clamped a level to both fences to make sure it stayed really flat and square.
Clamped the extension fence to the extension base and locked it down with moetising. Moved the sled to the other miter slot and just made the cut! This can also be mortising vs straight router bit note with a just a drill and a drill bit.
Maybe it would be better to glue the boards together before routing the slot in the center though. The reason notf I doubled up the thickness of this fence was to prevent tear-out on the backside of my workpieces. Whats cool about it is that once you cut the desired angle on one end, you can kortising that to lock it in place for future cuts.
And you can precut all 4 corners of the fence to angles that you commonly use by flipping it on its other side. Collapsible Bandsaw Bowls. Adjustable Dado Jig.
Geometric Veneer Record Player Stand. Sunburst Veneer Guitar. Hand Tool Sharpening. Interlocking Puzzle Joint. Pool Toy Storage. Modern Storage Bench. Multi Function Cross Cut Sled. Marble Solitaire Game. Three Piece Lap Joint. How to Make an Adjustable Doweling Jig. DIY Puzzles for Kids. How to Make a Custom Waterslide Decal.
Modern Bar Cart. Making Dowels without a Lathe. Shooting Board with Attachments. Waterfall Side Table with Storage Shelf. Hand Tools. Time for a new Cross Cut Sled! Check out the full build video below! The base is now complete! This can also be done on the table saw. Then I cut the base for the extension piece to size. This could also be done with dowels or a biscuit joiner. And into the oak strips. Now the locking mechanism is done! Time to assemble it! Next up is the bevel feature!
Super easy! Next I made the adjustable fence jig. Then I mortising vs straight router bit note those boards together and the jig is done!
Why I love this design: 1 The main sled is light enough for every day use. Happy Building! Email Address.
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blero
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