After entering the Box Swap knew I had to build a sled that cut near perfect 90's and 45 degree bevels, the sleds in the shop are not cutting true 90's anymore, they have gotten loose. After all these projects will be under the scrutiny of Woodworkers. Not your friends that wouldn't know a good glue line if they saw it, just "Oh my that is beautiful".
The base is 3/4" BB. Fence furthest away from you is 3/4" Maple plywood which was left over from the Display Case build. Original push fence was also made of 3/4" Maple plywood (2 Laminated layers) which eventually proved to be a bad choice, even though it was free (sorta).
Got the sled all built and semi adjusted with a triangle on the saw blade. Made the first 5 cut adjustment square and measured. But during the cutting of the 5 sides noticed the sides of the 7/16" MDF against the fence seemed to be bowed ever so slightly away from the fence face. Oh Sh#t, something is wrong. The screws had split the fence and bowed it. Knew that there were MDF layers in the Maple plywood and this occurring was deep back in my mind. So back up and rebuild the push fence. I had real maple hardwood left over from the box build, so 2 layer of 4/4 soft maple were used, squared them up and glued it together, and flattened and squared again. Voila!!! Yippee!!!
Went through the 5 cut adjustment steps and got the sled to 0.0007"/" which knew could be better, but..... boxes need to ship on March 11.
So onward with the box build. Going well so far, however dust in the shop made finishing problematic. But sanding those extra layers just makes for a thicker overall film. Went to the shop this morning at 8:15 am and put one coat on all sides and one on the inside before others came in and turned on saws. So now 3 coats on the outside and 1 inside.
This afternoon I returned to the shop to finish dialing in the sled. This is troublesome after the sled has been sawn all the way through end to end. I have done it before and this one I got completed in about an hour and a half. Like the 5 cut results, 0.0001364"/". Pretty happy with those numbers. Although the miters and 90's on the Swap Box are very nice.