I have been using the Proxxon mini table saw for a few years now and I have to say it is one of the best mini table saws on the market. It is portable and powerful, and the cuts are clean, accurate, and precise. The table saw is quiet, yet the machine is powerful enough to cut easily through softwood as well as various types of hardwood and plywood.
A mini (portable) table saw is the perfect tool for model making, toy making, creating small architecture prototypes, and any type of craft.
So… What should be the first addon for a mini table saw? Definitely, a mini table saw sled or a crosscut sled.
There are many benefits to using a table saw sled. The most important one is safety, but apart from that the sled improves accuracy, makes repetitive cuts easier, holds the workpiece in position, and overall allows you to work faster and more reliably.
I built the mini crosscut sled in a few hours, and this time spent is definitely worth it. A table saw sled is one of the most used woodworking jigs together with a table saw. The material for the build is easily available, the only thing you really need is plywood.
This is an easy project for woodworking beginners and a so much-needed jig for a table saw. You will see for yourself that working with a mini table saw will be much easier.
How to Make a Mini Table Saw Sled Video
If you want to see how it is done, watch the video below for a step-by-step guide on how to make a small table saw sled for a mini table saw.
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Table of Contents
- The Material you will need
- Small Table Saw Sled Plans
- General Questions
- What material should I use for a mini table saw sled?
- What saw blade to use with a mini table saw?
- How to make a Mini Table Saw Sled (Mini Crosscut Sled)
- Step 1: Build the Fence
- Step 2: Make a T-track in the Fence
- Step 3: Make a Fence Support
- Step 4: Make a T-track Stopper
- Step 5: Add Runners for Table Saw
- Step 6: Add a Self-adhesive Scale Ruler
- How to Use a Mini Table Saw Sled
- Woodworking Jigs Used for the Project
*Safety is your responsibility. Make sure you know what you’re doing and take all necessary safety precautions while working with power tools. Safety comes first!
What you'll need to make a Mini Table Saw Sled
Material – Birch Plywood, MDF, Beech
Mini table saw sled – fence back
Plywood – 240 mm x 60 mm x 12 mm – https://amzn.to/4aOWVva
Supports – 4x – 40 mm x 30 mm x 1 mm
Mini table saw sled – t-tracks
MDF Strips – 240 mm x 30 mm x 4 mm; 240 cm x 22 mm x 4 mm – https://amzn.to/3voPCKL
Plywood Strips – 240 mm x 26 mm x 6,5 mm; 240 mm x 19 mm x 6,5 mm – https://amzn.to/3HeFJla
Mini table saw sled – runners
Beech strips – 240 mm x 8 mm x 7 mm
T-track Stopper – 60 mm x 30 mm x 12 mm
Tools:
Proxxon Table Saw
Circular Saw – https://amzn.to/4aMD0xg
Cordless Hand Drill – https://amzn.to/3HqLEnH
Trim Router – https://amzn.to/3HbQcOg
Cord Drill – https://amzn.to/3NSA3Bo
Chisel Set – https://amzn.to/3tHNJrT
Machinist Square / Speed Square
Spring Clamps – https://amzn.to/41Nuh9D
F-Clamps – https://amzn.to/48ArzY1
Other:
6mm Drill Bits – 6mm – https://amzn.to/48Kaaf7
Router bits – 15mm – https://amzn.to/3NQNDVX
Wood Glue – https://amzn.to/48ltKhJ
Epoxy – https://amzn.to/3tJ5R4L
Adhesive scale ruler – https://amzn.to/3TTjGZb
M6 Wing nut, M6 Bolts, Wood Screws – https://amzn.to/41PodgQ
Check all the Tools I Use
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What material should I use for a mini table saw sled?
The main components of a mini table saw sled should be made from plywood. Birch plywood is the best option. It is a high-quality material and its use will contribute to the quality of the final product.
Other parts, such as the t-track or the stopper can be made either from plywood or MDF. For the runners, it is recommended either to use hardwood strips (oak, beech) or plastic strips. Both materials don’t react as much to external conditions and do not expand or contract when the ambient temperature changes.
RELATED: Basic Types of Wooden Boards
What saw blade to use with a mini table saw?
There is no need to frequently change a blade on a mini table saw. With a mini table saw you will be mainly cutting smaller and thinner pieces of wood, so a universal blade is fully sufficient and will work both for rip cuts and cross cuts.
A universal blade will also be suitable for cutting through plastic or other types of soft materials. For special materials such as glass, stone, or metal it is good to use other suitable blades.
Let's Start Building!
The body of the mini table saw sled is made of birch plywood and MDF and the t-track runners are from beechwood. There is no baseboard so as not to take away from the already small saw blade. If the saw sled contained a baseboard, I would use a 3mm MFD desk, which would be completely sufficient.
The overall dimensions of the saw sled are 240 mm x 80 mm x 60 mm. It can be easily mounted and removed from the table saw. There is a stopper running in a t-track which makes it very easy for any repetitive cuts.
Also, it is worth making a chamfer at the bottom of the crosscut sled (where the sled meets with the table saw surface) to divert sawdust away when cutting. Thus, the crosscut material nicely adjoints both to the saw sled and to the stopper resulting in perfectly identical repeating cuts.
I used a few power tools to build the saw sled – a circular saw, a trim router, and a hand drill, however not all are needed.
How to make a Mini Table Saw Sled (Mini Crosscut Sled)
Step 1: Build the Fence
First, measure and cut the pieces for the saw sled fence and the fence t-track – plywood back piece (24 mm x mm x 12 mm), plywood strips (24 mm x 26 mm x 6,5 mm; 24 mm x 19 mm x 6,5), MDF strips (2,4 mm x 3 mm x 4 mm; 24 mm x 22 mm x 4 mm).
To cut all the parts I was mainly using a circular saw with a circular saw track, though the table saw would work just fine as well.
Step 2: Make a T-track in the Fence
Cut a shallow slot for the self-adhesive scale ruler in the upper MDF strip. The best way how to cut a clean slot is by using a router with a dado jig.
Build the t-track in the saw sled fence by gluing all the strips on top of each other. When using this t-track creation method it is important that excess glue does not remain in the slot. Use only as much glue as needed.
TIP: Use a reference piece of wood or a lever, which will serve as a stopper when during wood strips.
Additionally, you can secure the fence and the t-track with screws.
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Step 3: Make a Fence Support
Reinforce the back of the fence with a few plywood pieces and add a cover for the saw blade. SAFETY FIRST!
Use a square to make sure the fence is perpendicular to the table.
Step 4: Make a T-track Stopper
Cut a thin plywood strip (3 mm x 15 mm x 6 mm). Drill a 6mm hole in the center of the piece and carve a hexagon around the hole for the bolt’s head.
Depending on the thickness of the head you might need to grind it a bit so it is nicely flush with the surface.
Insert the bolt in the hole and use epoxy to fix it in place. After the glue dries slide the bolt into the t-track.
Cut a plywood piece for the t-track stopper and drill in a 6mm hole exactly at the level of the fence t-track. Mount the stopper on the t-track bolt and secure it with a wing nut.
Step 5: Add Runners for Table Saw
Cut beechwood strips so they fit nicely in the table saw tracks. They need to slide on the track easily but there must be no room for any wobble. (I didn’t have to cut them since I found the exact width at the store).
To make sure the strips are flush with the saw table I ran the strips several times through a piece of sandpaper.
In order to glue the runners to the saw sled insert washers in the table saw tracks first and place the runners on top of them.
Apply epoxy on the runners and use a square when placing the fence on the runners to make sure it is perpendicular to the saw blade. MAKE SURE THE TABLE SAW IS UNPLUGGED.
After the glue dries cut a notch in the fence.
Step 6: Add a Self-adhesive Scale Ruler
Once finished with the runners add a scale ruler on the saw sled fence.
Below is a picture of a finished mini table saw sled for a mini table saw. A table saw sled is one of the top 3 woodworking jigs for a table saw and you won’t make a mistake if you make this jig as one of the first ones.
How to Use a Mini Table Saw Sled
Provided steps below describe how to set up and how to use a mini table saw sled in combination with a mini table saw.
Take all safety precautions. Even though a mini table saw does not have the same power as a standard table saw, it can cause severe injuries. Keep that in mind and work accordingly. Use push sticks or push blocks while operating a table saw.
A mini table saw sled is a perfect table saw addon for any kind of model making, small designs, or prototypes. A mini table saw is powerful enough to cut through hardwood and accurate enough for delicate cuts.
The best use of a mini table saw sled is for making short cross cuts safely, cutting precise wooden pieces, and ensuring clean square cuts every time. A table saw sled reduces the chance of kickback and allows cutting small wood pieces without fear of injury.
Using a mini table saw sled
- Place the mini table saw sled securely onto the table saw, ensuring it sits flat and is well-aligned with the blade.
- Double-check that the runners fit snugly and slide smoothly in the table saw tracks, ensuring accurate and straight cuts.
- Inspect the cut path to ensure there are no obstructions or debris that could interfere with the cutting operation.
- Position the stopper at the desired location, and lock it securely to ensure consistent cutting lengths.
- Insert your workpiece into the saw sled, gently pressing it against the saw sled fence to guarantee a straight, precise cut.
- Adjust the height of the table saw blade to match the thickness of your workpiece, ensuring a clean cut through the material.
- Hold the workpiece firmly in position, and gradually make the cut by smoothly pushing the sled along the tracks, maintaining a steady pace to ensure an even and accurate cut.
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I hope the information shared in this blog post inspired and now you are adding this table saw jig to your next builds. 😉
