Let's Go Sledding!

This morning I spend some time down in the workshop getting a few projects done that I have been putting off for some time: table saw sleds and painting the viking chair. I made two sleds for the saw, a crosscut sled and a panel sled. The first step in making sleds is to make your runners that go in the miter slots. I used a small piece of purpleheart I picked up at Woodcraft for my runners.

Purpleheart runners. It is much more purple in person.

This was my first time working with actual hardwood and it is much different to work with than the pine that I am used to. I made sure to pre-drill all of my screw holes so I wouldn't split the wood. I cut runners to fit in the 3/8" x 3/4" miter slots on my table. Working with such small pieces can be dangerous so always exercise caution. I also made a featherboard to help hold the work pieces against the fence for more uniform cutting. The first one didn't turn out so good, especially since there was a knot in the board and the feathers just broke off. The next attempt was much better as I cut the end at an angle and it was a narrower board to work with.

The first featherboard didn't quite work out. Note the knot.

The second iteration. Angled at 30 degrees.

Clamped to the miter gauge to guide the runners in.

After the runners were made I moved on to the base of the sled. I used 1/2" MDF cut to about 34" wide and 24" deep. I placed the runners in their slots and put the base on top, aligning all three pieces with the edge of the table. I pre-drilled and countersunk the screws to faster the base to the runners.

Cutting the base to size from 1/2" MDF.

Lining up the runners and base before attaching.

Attached with pre-drilled and countersunk screws.

Next was the front and back of the sled which I made from two pieces of 3/4" MDF laminated together. The back is the only one of the two pieces that really needs to be aligned properly. I cut a small slot in the base with the table saw and lowered the blade back down. I placed a scrap piece of lumber in the slot and used a large square to align the back fence with the saw slot. I roughly followed what Marc Spagnuolo from The Wood Whisperer shows in this video. When laminating the fences, I broke a couple of my cheap Home Depot clamps. Looks like I need some nicer ones in the near future.

The finished sled. A bit heavy.

I need more clamps!

The second project was a small panel sled. This was made using a lot of the same principles but only occupies one side of the table.

Attached the purpleheart runner.

Using my largest square to align the fence.

Complete!

And finally, the painting of the viking chair! I am using General Finishes Emerald Milk Paint. I put two coats on after doing some additional sanding I did not complete last time.

First coat of Emerald.

I would like to build a few more featherboards, but I will just make them when I need them as they only take a few minutes to cut. I bought this air nailer set from Woot at a good price and I plan to use the brad nailer for the bookcase and attaching the edge finish on my computer desk.