When my dad inherited my hybrid tablesaw he also got a couple of sleds. One of them was a small one that I call my 'box sled' although it is used for many other smaller cuts. I am waiting on a finishing stage to cure on a few pieces which will take couple of days so I am free to take care of replacing this little guy. It is about 24" x 16" with about 12" of usable space between the front and rear fences. This makes it a build that can eat up some of my scrap. I usually use hardwoods for the fences but, in the spirit of cleaning out the scrap bin I will use BB ply for all of this.
My original "I'm-gonna-make-a-better-version-someday" dado jig built from an old bookcase is still getting used(???). *** [small voice in head] maybe I oughta take care of that between larger projects too ***
Anyway, here is the dado jig in use making the stopped dados that will hold the t-track. I also use it to hog out the ZCI strip location.
The "fence" pieces in the last pic are just some scrap I set there to make sure I am not wandering too far afield. The overlong ZCI insert is from my 'medium' sled and again is just a prop for the pic. The fences will actually be laminated BB ply pieces that I am waiting for the glue to set up. I just wanted to see the track in place. I will also laminate a dummy block for the blade exit location. Primarily used to cut mitered ends for small boxes it is also handy for any light crosscutting job that requires extra accuracy.
When I make the inserts for any jig, I make a bunch as the setup takes the time and not the actual making. Since all my sleds use inserts of a common width I made some extras for the medium sled too. The large sled goes through these the slowest and i still have plenty.
To drill the through holes in the fence I make sure everything is nice and square. A couterbore allows the washer and nut to set below the top to stay out of the way of any clamping or what-not.
And here it is partially assembled. I have to stop for some dinner and will pick this up tomorrow.
Ok, so among other things as mentioned, this is one thing it excels at; easy, air-tight, mitered edge boxes.