Easy Joinery with a 45-Degree Mitre Table Saw Sled

Woodworking is all about precision, and nothing helps achieve that better than a well-crafted tool you make yourself. In this guide, we’ll show you how to create two essential woodworking aids: a 45-degree mitre sled and a pallet wood joining sled for your table saw. These DIY tools are simple to build, cost-effective, and will level up your woodworking game.

Why Make Your Own Sleds?

Store-bought sleds can be expensive, and they might not fit your specific needs. Building your own ensures a custom fit for your table saw, and it’s a fantastic opportunity to learn or refine your joinery skills. Plus, creating your tools is incredibly satisfying—it’s the ultimate “DIY within a DIY” experience!

Materials and Tools Needed

You don’t need fancy materials for this project. Gather these basics:

Scrap or pallet wood
Plywood or MDF for the sled base
Screws, wood glue, and nails
Table saw
Sandpaper
Measuring tools (ruler, square, protractor)
Drill

Step 1: Creating the Sled Base

Begin by cutting a sturdy piece of plywood or MDF to serve as the sled base. Ensure it’s slightly wider than your saw blade and long enough to support your workpieces. Sand the edges for a smooth finish.

Step 2: Adding Runners

The runners are crucial for guiding the sled along the table saw grooves. To make them:

Measure the width of your table saw’s grooves carefully.
Cut thin strips of wood to fit snugly into the grooves.
Attach these strips to the bottom of your sled base using screws or glue, ensuring they align perfectly for smooth sliding.

Step 3: Building the 45-Degree Mitre Sled

For accurate 45-degree cuts, follow these steps:

Attach a back fence to the sled base at a perfect 45-degree angle using a square or protractor. This is critical for precision.
Secure the fence with screws or glue. Reinforce it with triangular braces for stability.
Test the sled by making a few cuts, adjusting as needed to ensure accuracy.

Step 4: Crafting the Pallet Wood Joining Sled

This sled is ideal for joining rough pallet wood pieces. To make it:

Attach a straight-edge fence perpendicular to the blade.
Add clamps or holders to secure the pallet wood during cuts.
Sand and finish the sled to prevent snags when sliding wood across it.

Step 5: Testing and Fine-Tuning

Once your sleds are assembled, it’s time to test them. Slide each one along the table saw, ensuring smooth movement and precise cuts. If needed, sand or adjust the runners and fences for a perfect fit.

Tips for Success

Safety First: Always use push sticks and proper safety gear when working with table saws.
Check Measurements Twice: Precision is key, so take your time during setup.
Repurpose Materials: Scrap and pallet wood are excellent for this project, keeping costs low and reducing waste.

Benefits of DIY Sleds

By making your own 45-degree mitre and joining sleds, you’re not just saving money; you’re building tools that fit your unique projects. These sleds make joinery easier, faster, and more accurate, whether you’re working on fine furniture or pallet wood creations.

So, roll up your sleeves and dive into this rewarding project. With just basic materials and a little effort, you’ll create essential woodworking tools that’ll serve you for years to come!