Circular Saw (corded)
- 1 Plywood , 3/4" Thick , Half Sheet
- 1 Board , 2x4 , 6"
Hardware & Supplies
- 1 Kreg Precision Stop Kit
- 2 Kreg Mitre Slot Jig & Fixture Track
- 1 1 1/4" Drywall screws
Break down your sheet goods into manageable lengths using your choice of a table saw (or circular saw. It is recommended to use a guide system with a circular saw. create your cut list to the designated dimensions.
Pre drill and countersink one of the 20" x 4" piece of ply and glue and screw it to the other to create the back support for the sled
Attaching Mitre Tracks
lay your mitre tracks in your mitre slots on your table saw. Then align your fence to 20" so the blade is centered in the sled ( you can adjust this for your own preference if you would like, I chose the center because i wanted 20" to the left of the saw blade)
Attaching Mitre Tracks pt.2
Align the front of the sled base with the front of the mitre slot tracks. Screw the first one in using the proper length screws, and making sure to keep the base flush against your fence. After you fasten the first screw, slide the sled out and fasted the second, then flip the whole sled over for the final screw. This isn't particularly important it is perfect because you can adjust the fence later. Make sure the sled slides smoothly and adjust your tracks accordingly.
Attaching Front Fence
Attaching the fence at this stage is simple. Counter sink a hole at each end of the base and fasten the 2 1/4" thick board to the back of the sled on each end. Do not over tighten, this pivot will be how you adjust your sled in the next step.
Raising The Blade
Raise the blade slowly through the center of the sled making sure to keep your hands clear. Once the blade breaks the surface go ahead and slide the sled forward and back to give a reference of where the blade will be. DO NOT CUT THE WHOLE WAY THROUGH THE BASE OF THE SLED ON EITHER SIDE!!!!
Attaching Back Fence
Attach the back support. Make it as square as possible, this piece isn't used for reference and is not 100% crucial to be perfectly square. So give it your best judgement, countersink and fasten using screws.
Squaring The Sled
Using the 5 cut method, square a piece of scrap wood on the saw as it stands. Make any adjustments needed to square the sled. Once adjusted , countersink and fasten down the fence.
There is a link in the extras folder for the 5 cut squaring method in great detail
Attaching Stop Track
Pre drill your precision track and attach it to the fence. You will need to cut 8" off of one of the track pieces to fit this 40" sled, this can be done on your mitre saw. The metal is soft and easily cuts.
Add the support piece to the rear of the sled using countersunk screws. Avoid screws near where the blade intersects the fence.
Countersink and attach the 6" x 2 1/2" piece of 2x4 where the blade exits the back of the sled.
Waxing The Sled
Wax the base of the sled with a paste wax and you're all done!