Table Saw Miter Sled for Aluminum Extrusions

In woodworking there are many ways for cutting perfect miters. This is my approach.

Assembly

The printable piece is designed to attach two standard 30x30 aluminum extrusions. Each might be attached by two M8 20mm Screws and some t-nuts. The assambly then just gets screwed to a table saw sled base and you are pretty much done. In my build I additionally attached some HPL covers to the fence. But this is optional.

About accuracy

Depending on your printers quality, your piece will come out more or less accourate. Even on my Core One I had some slight overextrusions, which would had thrown off my sleds accouracy. So you might need to manually adjust the print a bit.

For that I designed some ‘lips' on the outer shell. These can be cut slightly to establish a perfect plane. I used a well calibrated shooting board and a sharp plane for that. Alternatively you also could use shims under the extrusions to tweak accuracy.

Stop Block

To make repeatable cuts on this sled I also designed a micro adjustable stop block. It includes an extra wide fence, so the miters can be referenced to it. Also it works perfectly for aluminum extrusions. You can get the files here: 

https://www.printables.com/model/1472010-stop-block-with-micro-adjustment