Replies

1. 
   jackplane | Jan 07, 2005 10:54pm | #1

   The easiest is to use 3/4" birch  ply or other plywood, no need for expensive hardwood. And use braces to strengthen it.

2. 
   mvac | Jan 07, 2005 11:07pm | #2

   Tom,

   I used 1 1/2" hard maple, laminated from two 3/4" boards, for both fences. My sense is that the lamination helped warp resistance (I built the sled 7 years ago, and it still works like a charm). One thing I'd do differently today if I were building one from scratch, although it isn't irritating enough to cause me to do it on my current sled, is use UHMW for the runners. Ultra high molecular weight material has great "lubricating" ability - it slides as if it were oiled steel. And for this purpose it's as durable as the hardwood runners - I also used maple for those, with no ill effects.

   I'm not sure that grain orientation makes a big difference, since I imagine you'd build the fences with the grain running parallel to the base and perpendicular to the blade. That said, I attached the radial face to the sled, with the tangential faces providing the surface against which I butt my work. I'd be interested to know if anyone else thinks the reverse approach would be less stable or effective.

   Hope this helps,

   Mitch

1. 
   sawdustom | Jan 10, 2005 05:39pm | #4

   Thanks for the "laminating" tip - this makes a lot of sense. Maple makes sense as well - I like its durability.

1. 
   mvac | Jan 10, 2005 09:01pm | #5

   Tom,

   Glad I could help. Considering the amount of time I ask for and receive info from this board, it's a welcome change.

   Mitch

3. 
   hammer1 | Jan 08, 2005 03:38am | #3

   I have a number of jigs I've had for years. They are usually cobbled together with whatever scraps are kicking around the shop. There are always plenty of pieces of 3/4" birch plywood so most of my sleds are made with that. I would recommend using something other than wood for miter way runners. Even though most are only 3/4" x 3/8", they will expand and contract through the seasons and not work as you want. I think my slides are from Incra, they have an adjustable expansion screw to customize the fit. If you use large or heavy solid stock for fences, there is a greater probability that they will move. I also like to use toggle clamps on some of my jigs, so I make fences that will accommodate their use.

   Beat it to fit / Paint it to match