Incra Miter 5000 (like) on a TKS80 with ST840 Sliding Table

[NZ3.14]

Hi,

I've been using a Rockler miter sled on the original and much smaller TKS80 sliding table - It has worked well, and cuts are repeatable as long as the sled has not been removed from the table.

I've invested in the larger ST840 sliding table, as it allows for much finer alignment on the saw. After investing an hour or two, I'm very pleased with a front-to-rear delta of 0.009 mm.

I've made a slightly wider variation of the Incra 5000 sled, using 16mm HP Laminate-Lite ply. It is attached to the sled via a 300 mm-long bar that has been machined to align and lock into the channel on the sliding table. This bar is secured via two shoulder bolts that mate with two brass bushings, which are recessed in the ply with no play.

While the sled is reasonably wide, mounting and removing from the saw is easy. It is placed on the top of the saw with the 300mm bar in the open space between the left side of the TKS 80 and the sliding table, the sliding table is moved to its lowest position and the miter sled is moved to the left allowing the bar to slide into the channel on the sliding table easily. It is locked in place with two turns of the shoulder bolts.

I also have a mitre slot to the left of the blade, which is used to hold the out-feed ply in place.

I was surprised when my first cut delivered a perfect 90-degree cut!

The sled is stored in the box on the lower right of the table.

Pictures should help to tell the complete story. Please reach out with any questions.

The extra holes on the bar were a first go at attaching the gauge directly to the sliding table, which also worked, but I wanted a way to hold what was being cut safely closer to the blade.

Thanks.

 

[smorgasbord]

Nice setup. Is the Incra fence extension long enough to keep the second support in the left T-Track at 45º? If not, you could angle that T-Track inwards away from the fence. Which also has the side benefit of saving some weight.
I myself do like the Incra system for setting up repeatable stops. Here's a thread where I added a micro-adjuster to it:

S

Thread 'Modifying an Incra Flip Shop Stop for better micro-adjust'

Nov 27, 2024

I don't know if many here use Incra rails with their flip stop on a miter saw station or cross-cut sled like I do. I really like the racks for accurate and repeatable lengths (I'm using the red metric 1mm racks), but there are times when one needs to cut on a half mm or trim something off multiple pieces.

The built-in micro-adjuster is a really bad design:
[attachimg=1]

Not only is it inconvenient (you have to loosen two cap screws on top then turn the adjuster screw, then lock-down), it also messes with your calibration in that if you don't remember exactly how much you turned the adjuster you'll...

• smorgasbord
• Replies: 8
• Forum: Other Tools & Accessories

 

[NZ3.14]

Thanks for the micro adjuster pointer - I have a longer fence dug away somewhere, just have not had a chance to dig it out.

 

[kevinculle]

0.009mm is 3.5 ten-thousandths of an inch! Are you building optical interferometers out of wood?

 

[NZ3.14]

Nope… possibly a little lucky with the tuning!

 

[smorgasbord]

Nope… possibly a little lucky with the tuning!

I think the real question is how you measured a right angle wooden board that accurately. That Woodpecker's square in one of your photos is accurate, but not that accurate (claim is +/-0.0254mm along a 450mm length for its largest square). You're claiming a full order of magnitude better than that for something made of wood.

 

[luvmytoolz]

When I do inlay work, I find anything less than 0.05mm is indistinguishable from nothing.

 

[NZ3.14]

Two screenshots of a video showing the results.

 

[Andy99]

Hi,

I've been using a Rockler miter sled on the original and much smaller TKS80 sliding table - It has worked well, and cuts are repeatable as long as the sled has not been removed from the table.

I've invested in the larger ST840 sliding table, as it allows for much finer alignment on the saw. After investing an hour or two, I'm very pleased with a front-to-rear delta of 0.009 mm.

I've made a slightly wider variation of the Incra 5000 sled, using 16mm HP Laminate-Lite ply. It is attached to the sled via a 300 mm-long bar that has been machined to align and lock into the channel on the sliding table. This bar is secured via two shoulder bolts that mate with two brass bushings, which are recessed in the ply with no play.

While the sled is reasonably wide, mounting and removing from the saw is easy. It is placed on the top of the saw with the 300mm bar in the open space between the left side of the TKS 80 and the sliding table, the sliding table is moved to its lowest position and the miter sled is moved to the left allowing the bar to slide into the channel on the sliding table easily. It is locked in place with two turns of the shoulder bolts.

I also have a mitre slot to the left of the blade, which is used to hold the out-feed ply in place.

I was surprised when my first cut delivered a perfect 90-degree cut!

The sled is stored in the box on the lower right of the table.

Pictures should help to tell the complete story. Please reach out with any questions.

The extra holes on the bar were a first go at attaching the gauge directly to the sliding table, which also worked, but I wanted a way to hold what was being cut safely closer to the blade.

Thanks.

Cool solution you did for the Rocket miter sled.
I have the smaller sliding table, ST TKS80, will see if it is possible to do something similar.
To the right of the saw I seem to glimpse an Incra fence together with a self-made table, is that right?
Would be interesting if you want to share your set up around this.
Would love to do something similar and would appreciate getting inspiration from your build.

 

[NZ3.14]

Hi,

I will send an update on both of your questions when I have a moment.

See an earlier post where I showed how I added the sled to the smaller sliding table...

N

Thread 'Mitre Sled for TKS 80'

Dec 13, 2021

I've added a mitre sled to the TKS 80 sliding rail.

This was done with the help of two additional parts:

Festool Crown stop AB-KS 120 (2 units)
Large 'nuts' that fit within the channel in the Crown Stop

I could have used an M8 square nut but wanted to reduce as much play as possible.

The result works well!

I will add a fixed board to the other side of the blade as a temporary fix until a construct a 'full sled that covers both sides of the saw blade.

The sled can easily be removed and attached by sliding onto the sled and tightening the stops.

Reach out with any questions.

-Philip

• NZ3.14
• Replies: 7
• Forum: Festool Jigs & Tool Enhancements

Please let me know if you'd like to acquire this sled

-Philip

 

[NZ3.14]

Hi,

Remembered that I also posted about the mitre slot in 2019.

N

Thread 'Adding a Miter slot to CMS Table'

Aug 24, 2019

Hi,

I've added a miter slot by way of the CMS extension table and an aluminum block.  The process was removing the profile on the underside of the table cover plate, machining the block so it would fit perfectly in the existing table side rails and would provide a guaranteed reference to the table for removal and insertion.  The block was then attached to the underside of the table cover plate and then the slot was machined.

Hope this is helpful to others!

-Philip

• NZ3.14
• Replies: 3
• Forum: Festool Jigs & Tool Enhancements

• 

Reachout with any questions

-Philip

 

[Andy99]

Hi,

I will send an update on both of your questions when I have a moment.

See an earlier post where I showed how I added the sled to the smaller sliding table...

N

Thread 'Mitre Sled for TKS 80'

Dec 13, 2021

I've added a mitre sled to the TKS 80 sliding rail.

This was done with the help of two additional parts:

Festool Crown stop AB-KS 120 (2 units)
Large 'nuts' that fit within the channel in the Crown Stop

I could have used an M8 square nut but wanted to reduce as much play as possible.

The result works well!

I will add a fixed board to the other side of the blade as a temporary fix until a construct a 'full sled that covers both sides of the saw blade.

The sled can easily be removed and attached by sliding onto the sled and tightening the stops.

Reach out with any questions.

-Philip

• NZ3.14
• Replies: 7
• Forum: Festool Jigs & Tool Enhancements

Please let me know if you'd like to acquire this sled

-Philip

Hi!
Thanks for your reply!
You have very smart and interesting solutions, will be exciting to see how you have solved the setup with Incra LS.
Keep up your great work!