How to make a small table saw sled with built in t-track, toggle clamps, and stop block. A simple crosscut sled can be used to make accurate 90 degree cuts on the table saw and allow you cut small pieces safely.
I made the runners from UHMW plastic (low friction) since they are less likely to warp or twist. The track is 1/4″ mini t-track from shop fox, and the flip stop is from peachtree woodworking. My favorite features are the Bessey auto-adjust horizontal toggle clamps. They were a bit pricey, but they are well built and easy to use. I modified them to slide onto the track with more UHMW plastic and brass threaded inserts for 1/4″ bolts.
My finished sled was precise to .02″ inches over 4ft (using the 5 cut table saw sled test for accuracy). If I want, I can easily shim the back fence and probably cut that in half. The size ended up being 24″ wide and 15″ tall/deep.
Very well done, dude! I do like me some good craftsmanship. I’ve been woodworking for a few years, but not getting too awfully serious until recently – built a nice headboard for my wife. I have occasionally wondered what those wide grooves in my table-saw top are for — now I know! Excellent work, Mike.
Thanks!