This project was built and designed by Joe Heide from Woodworkers DiyLemma. It’s a compact miter sled built for the table saw—ideal for producing clean, consistent 45-degree cuts, especially when building boxes.
With just a few pieces of scrap plywood and some thoughtful alignment, Joe demonstrates how this simple jig can take your miter joints to the next level. Whether you’re new to box making or looking to tighten up your angles, this is a useful addition to any shop.
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Why a Miter Sled Matters
A miter sled allows for controlled, repeatable angled cuts on a table saw. It supports the workpiece and keeps hands well away from the blade, making it safer and more accurate than trying to freehand miters or use a standard miter gauge.
This type of sled is especially useful for box making, where small variations in cuts can cause corners to open up or misalign. Joe’s version of the sled is small enough to handle easily but sturdy enough to handle repeat cuts with precision.
Materials and Setup
Joe builds the sled using birch plywood and a strip of Teflon. These materials are often available in the scrap pile of many workshops, which keeps the cost low and the project sustainable.
The base of the sled is cut first and serves as the foundation. Joe attaches the Teflon to the underside of the base, allowing it to glide smoothly across the table saw’s surface. This small addition makes a big difference in ease of use and overall accuracy.
A guide board is then mounted on top of the base. This board runs parallel to the saw blade and acts as the reference fence. It’s secured with screws to keep it in place and reduce any flex or movement during cutting.
Dialing in the Angle
Getting the angle right is the heart of this jig. Joe shares a straightforward method to align the sled precisely to the blade, making sure the cuts come out at a perfect 45 degrees.
He checks the alignment by making test cuts and examining the resulting miters. With small tweaks and careful adjustments, the sled is tuned until it delivers a flawless joint. No guesswork—just simple refinements to lock in the angle.
Making the Cuts
Once the sled is set up, Joe demonstrates how to use it to make corner cuts for a box. He positions each workpiece against the guide and carefully slides the sled across the blade.
What stands out in this process is the repeatability. Each cut comes out the same, with no need to reset angles or re-measure. This consistency is what makes the sled such a powerful tool for small projects like keepsake boxes, trays, or frames.
It’s important to keep firm pressure against the guide throughout the cut to prevent shifting. Joe also recommends checking the edge of the workpiece for square before each pass to maintain the tightest possible fit.
Checking the Results
After cutting, the difference in accuracy is immediately noticeable. The mitered corners join together cleanly, with no gaps or uneven surfaces. This kind of precision not only improves the appearance of the box but also increases its strength.
Joe dry-fits several corners together to show how well they align. This visual feedback is a great way to confirm that the sled is dialed in correctly before moving on to final assembly.
Advantages of a Mini Miter Sled
There are several clear benefits to adding this jig to your workshop:
- Precision: Clean, gap-free joints with minimal adjustment
- Repeatability: Make multiple matching cuts quickly and reliably
- Safety: Keeps hands clear and the workpiece steady
- Affordability: Uses scrap wood and simple materials
- Compact Size: Easy to store and pull out for small projects
This version of a miter sled is especially well-suited to anyone building boxes or picture frames, where even minor errors can be visually obvious.
Shop Tip: Keep it Simple
One of Joe’s key takeaways from the project is that precision doesn’t require complex setups. A small sled like this, built from scrap, can outperform store-bought jigs if it’s carefully aligned and used consistently.
The materials are accessible, the process is quick, and the payoff is huge when it comes to fit and finish. It’s a tool that keeps giving back every time you reach for it.
A Handy Jig Worth Having
Joe’s mini miter sled is a perfect example of a small project with big benefits. It’s straightforward to make, easy to tune, and immediately useful for a wide range of woodworking applications.
Whether you’re working on decorative boxes or just want better mitered corners in your projects, this sled is worth the hour or two it takes to build.
Watch the full video and subscribe to Joe’s channel: