This is the larger of three table homemade saw sleds I use in my shop. I call it the “Mega Sled” because it will do it all including crosscutting large panels and cutting various types of joinery.
It includes plans for a clever system of joinery jig attachments including a finger joint jig, a pair of dovetail jigs, a tenon-cutting jig, a jig for cutting spline slots to reinforce frames and boxes, and spring activated micro-adjusters to fine tune your cuts. It is by far the most capable table saw sled system around!
This large sled will work on any contractor’s table saw or cabinet saw. It will also work on many portable jobsite saws. It may be too large for some small benchtop saws. We offer a smaller version of this sled, complete with all the same attachments in our web store.
You may also purchase this sled, our smaller version (for day-to-day work) and our special miter sled (for 45-degree frames and boxes) as a set at a discounted rate in the “table saw jigs” catagory of our project plans store.
- Deluxe PDF Plans (Dimensions, cut list, drawings, build photos and step by step instructions)
- Dimensions: Inches
- Tools required: Table saw, pneumatic nailer, drill, router
Mega Sled Overview:
Jig Attachments Overview:
How to use the finger joint jig attachment:
How to use the tenon jig attachment:
How to use the dovetail jig attachments:
How to make and adjust the runners:
More about our deluxe plans:
Our deluxe project plans are more than just a set of dimensions. They include a comprehensive set of step-by-step instructions with dozens of photos and illustrations to walk you thorough the build.
You will NOT receive a paper plan. You will be sent a link to download a digital PDF document that is compatible with most computers and digital devices. You may print it yourself or take it to a printing service. We do not provide 3D Sketchup models or CNC G-code.
Below are some examples of what our deluxe project plans look like. This plan will be similar.
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This may be the only clamp rack you ever need. It will hold between 20-40 clamps, depending on the type, including F-clamps, parallel clamps, pipe clamps, bar clamps or pistol grip clamps. Set up the rack according to the types you own now. If you get more of a different type later, the rack adjusts to always efficiently use the valuable wall space. And it only requires a half sheet of plywood!
This is a tool Stumpy has wanted for a long time, but just couldn't justify the $1,000 price tag for the commercial version! It's a hand held mortising machine designed for loose tenon joinery- which is a lot like traditional mortise and tenon joinery- but WAY faster and easier! Inspired by the Festool Domino, this homemade version is a lot easier to make than you'd think, and it has more uses than you'd imagine!
This machine was born out of frustration! Stumpy had a cheap hand-held biscuit joiner that he picked up on a whim at Harbor Freight. The problem with cheap units like that is the difficulty that comes with making an accurately placed slot without the tool rocking out of position during the cut! So, like any good woodworker, Stumpy set out to find a solution. And the result is a bench top unit that can make a cheap tool into something easier to use than even the expensive hand-held versions. The Bench-top Biscuit Joiner is fast and accurate, inexpensive to build, and has dozens of uses. It's great for edge gluing boards, strengthening any butt joint, cutting slots for raised panels and picture frames... you name it!
Andre Roubo was among the oldest of the old-timey woodworkers, and the unique drawings found in his eighteenth century book have inspired woodworkers for over 200 years. Stumpy has designed a version of this bench which is by far the easiest, least expensive version to make. You can build one without difficult joinery, and without compromises in strength and features, all from cheap construction lumber! It's big, beefy and full of all the features a hand tool woodworker, or even a power tool woodworker, would appreciate.
This fence is truly unique with an innovative locking system that self squares to the blade, a micro adjuster for fine tuning your cuts, and an anti-kick-back European style with detachable extensions. Even the rails are made from wood! It's designed to fit any saw from small, bench top units to large cabinet saws, with or without side tables. There's even a built in pencil & accessory holder! (This project can be used on its own, but it is also designed to fit our deluxe table saw workstation)
Router planes are amazing tools, but they are also largely misunderstood. And that's a shame, because they are extremely useful in both a hand-tool and a power-tool workshop. Rather than cutting profiles, as a modern router does, a router plane is for cutting to depth with precise accuracy. They can be used to make the bottom of a table saw dado perfectly flat. They can fine tune a rabbet or a tenon. They are the perfect companion to many power tools with nearly unlimited uses.
My version of the router plane is easy to make from a scrap of wood and some easy to find hardware. And unlike other homemade versions, this has a micro-adjuster to set the depth and shaving thickness.
This rack was created with that in mind. It is designed to evolve with your collection. Not only can you move the bits around, you can also move the holes! This makes it possible to group bits by type, to add more places for 1/4-inch or 1/2-inch shaft bits, and each bit holder is removable so you may keep the bit protected when you take it to your bench or router table. This may be the last bit rack you ever build!
These two jigs are easy to make, and simple to use. One is for the router table, the other is used with a hand-held router. Both will cut through-dovetail pins (the tails are cut with a band saw, scroll saw or jig saw). The hand-held router jig will also enable you to cut half-blind dovetails as well. Both jigs are demonstrated in the videos below, and there's another video about laying out your joints.
These homemade spring clamps are easy to make, and cost almost nothing (assuming you have some scrap wood and rubber bands laying around.) They're great for light duty clamping, and make an excellent project for kids- just be sure to supervise while they use the band saw or scroll saw. The link below will provide you with patterns for a large and small version.
This amazingly accurate and versatile router table fence is patterned after the very expensive Incra LS system. It features a set of interlocking teeth creating positive stops every 1/16". You can't miss your mark even by the tiniest fraction of in inch! And when combined with Stumpy's "sliding router table" you can create precise joinery! It also works on any router table and is the most accurate homemade router fence out there.