Moving a project over. Pardon the dust.
This sled is based on eagle lake woodworking cross cut sled. It has everything I wanted.
The following link has build details and how to videos
I made a couple of changes to the original design:
1-I used 3/4 project grade plywood from Lowes instead of 1/2 called for in the design. I wanted something more beefy. Of course it is heavier.
2- I used plastic laminate on both sides. I wanted to have a more resistant surface. The plastic laminate slides better in my opinion. I also think it looks better. I can also write on it and erase it. I bought one sheet 4’x8’ from Lowes for $52. I have plenty left.
3- I changed the fence a bit especially in term of attachment. I did away with the track. The design I used allow me to have a stop much further from the fence without having a longer fence. I also don’t have to use flip stops.
4- I also shortened the moveable fences to my liking.
I have used this sled for a while and like it.
I cut a groove each half of the fence on the table saw using the regular blade in multiple passes. I did not feel like putting on a dado blade. I should have used a dado blade for a better groove.
glued those 2 halves together with a small piece of wood that fits in the groove at each end so that the 2 halves don’t move during clamping
once the glue dried, I used the jointer to get a face flat and one edge square. I the moved to the planer for the other 2 faces.
The final step was to cut a groove on the front face to act as a track for stops and accessories.
I scored the plastic laminate and bent it until it snapped.
I used a fence so I get it strait and to avoid tearing the sheet.
I applied contact cement to both the plywood an the plastic laminate. Waited until it became tacky then lay it into position with the help of dowels/rod.
I used the roller from one end to the other applying pressure and removing the dowels one at the time.
Once the dowels were all removed I rolled some more taking care not the crack the overhang edges with the roller.
I used a flush trim router bit with the palm router to flush cut the plastic laminated. I debated using a chamfer bit to ease the sharp edge or jus a sanding block. I opted for the sanding block. I think I will probably chamfer soon.
The moveable /miter fences:
The slots for the moveable fence were cut on the router table.
I marked the locations for the slots. Drill an entry hole and an end hole for the router bit and took several passes for each slot.
I bought a 3/4 wide 1/8 thick and 8 feet long aluminum bar from Lowes and cut 4 pieces from it for the moveable fences. I cut those on the miter saw.
Drilled and countersink the screw holes on the drill press.
Cut the fences to length and the 45 degrees angles on the end on my Sawstop. I used the key to de-activate the brake system.
Any suggestion to improve the design will be appreciated. Thanks for looking.
-- Abbas, Castro Valley, CA