This project was built and designed by Connor from Shopfix. It’s a straightforward, no-frills table saw sled that makes clean, precise 90-degree cuts much easier and safer to execute in any shop.
By using common materials and basic joinery, Connor shows how to build a highly functional sled without overcomplicating the process. This build is ideal for woodworkers looking to improve their cut accuracy without spending a lot of time or money.
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Why a Table Saw Sled Matters
A table saw sled is one of the most useful jigs a woodworker can make. It rides inside the miter slots and supports the workpiece on both sides of the blade, allowing for consistent, square crosscuts.
Connor’s design focuses on simplicity and precision. There’s no need for fancy hardware or metal runners—just accurate cuts, thoughtful alignment, and a few key techniques to get a dependable result.
Starting with the Runners
The first step is creating the runners that slide in the miter slots. Instead of relying on exact measurements, Connor cuts the runners slightly undersized and adjusts them as needed for a smooth glide.
A perfect fit is crucial. If the runners are too tight, the sled will bind; too loose, and it won’t cut straight. Sanding or planing the sides lets you dial in that ideal balance.
Building the Base Platform
The base of the sled needs to be completely flat and square. Connor starts by jointing one edge and trimming the panel to size with a table saw and miter saw.
This flat base will carry the workpieces and determine the accuracy of every future cut. It’s the foundation of the sled and deserves extra care when preparing.
Attaching the Runners
To attach the runners, Connor uses a clever trick—elevating them slightly with washers so they sit proud of the table saw surface. He then applies glue to the tops of the runners and carefully lowers the base onto them, aligning with the saw’s miter slots.
Paper shims are wedged into the miter slots to help center everything during glue-up. After allowing it to dry under weight, he flushes the runners and adds screws for additional strength.
Installing the Rear Fence
The rear fence adds rigidity to the back of the sled and supports the sled as it passes over the saw blade. After cutting it to width, Connor glues it in place and secures it from behind with screws.
It’s a simple but important step to keep the sled stable and square during use. Propping up the sled helps make this part easier to position and fasten cleanly.
Cutting the Initial Kerf
Next, the blade is raised through the base to create a kerf. This partial cut defines the path the blade will travel every time the sled is used.
Connor avoids cutting all the way through the front at this point, which helps keep the base intact until the front fence is added and aligned.
Squaring the Front Fence
The front fence is critical for ensuring perfectly square crosscuts. It’s cut to match the width of the base, and extra time is taken to position it exactly 90 degrees to the blade.
Connor temporarily clamps one end, then uses a square and double-sided tape to align a reference board. With everything in position, the fence is secured with screws and the blade kerf is completed.
Adding a Blade Guard
To improve safety, a blade guard is attached to the front of the sled. This simple block of wood prevents the blade from being exposed once it clears the fence.
Connor uses a 2×4 for this step, screwing it in place so it fully covers the blade path. It’s a quick addition that makes a big difference during repetitive cuts.
Testing for Accuracy
To test the sled, Connor makes a crosscut on a non-square piece of MDF and checks the resulting angle. If the sled is properly aligned, the cut should come out dead square.
This kind of accuracy helps with everything from trim work to box building. He also shows how a stop block can be clamped to the front fence for repeatable, identical cuts.
A Reliable Jig for Every Shop
This table saw sled isn’t flashy, but it does exactly what it’s supposed to do. It’s easy to build, reliable, and improves the precision of nearly every project.
Whether you’re working with fine furniture or just need consistent sizing on small parts, this jig is a worthwhile addition to any shop. Connor’s method keeps the process simple and repeatable for anyone.
Please support Connor by visiting his website: https://www.shopfix.services/.