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microjig ZEROPLAY User Manual

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ZEROPLAY Miter Bar 2-Pack Project Plans
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microjig ZEROPLAY Specifications

General IconGeneral
Brandmicrojig
ModelZEROPLAY
CategoryPower Tool Accessories
LanguageEnglish

Summary

Project Overview

Tools and Materials

Tools

Lists necessary tools for building the table saw sled, including router bits and safety equipment.

Materials

Details the required materials, specifying types and dimensions of wood and hardware needed for construction.

Sled Parts

Instructions

Step 1 - Cut Base and Wings

Instructions for cutting the main plywood base (PART A) and the top wings (PARTS B & C) to specified dimensions.

Step 1 - Cut Zero-Clearance Inserts

Details cutting the six interchangeable zero-clearance inserts (PARTS Z1-Z6) from plywood strips.

Step 1 - Cut Fence and Support Pieces

Instructions for preparing the hard maple pieces for the fixed rear fence (PART D) and center support (PART E).

Step 2 - Cut Dovetail Tracks for Inserts

Routing relief grooves and dovetail tracks onto the sled base (PART A) for zero-clearance inserts.

Step 3 - Drill Mounting Holes in Inserts

Procedure for marking and drilling mounting holes in the zero-clearance inserts for attachment.

Step 4 - Assemble Sled Parts

Attaching the zero-clearance insert to the sled base and gluing the top wings (PARTS B & C) in place.

Step 4 - Assemble Sled Parts Continued

Ensuring proper overhang of wings, removing the insert during gluing, and allowing glue to dry.

Step 5 - Route Dovetail Tracks in Fence

Cutting relief grooves and dovetail tracks into the fixed rear fence (PART D).

Step 6 - Trim Sled to Final Dimensions

Trimming the sled top (PARTS B & C) flush with the sled base (PART A) using a router and flush trim bit.

Step 7 - Route Dovetail Tracks in Sled Top

Routing relief grooves and dovetail tracks into the sled top for zero-clearance inserts.

Step 8 - Attach Fixed Rear Fence

Gluing the fixed rear fence (PART D) and fence center support (PART E) to the sled base.

Step 9 - Determine Miter Bar Location

Marking precise locations on the sled for attaching the ZEROPLAY Miter Bars.

Step 10 - Adjust Miter Bar to Slot Width

Assembling the ZEROPLAY Miter Bars and adjusting them to fit the table saw miter slot width.

Step 11 - Attach ZeroPlay Miter Bars

Drilling holes and attaching the assembled Miter Bars to the sled base, ensuring proper alignment with the blade.

Step 12 - Designate Zero-Clearance Inserts

Installing and cutting zero-clearance inserts to match specific saw blades for optimal performance.

Sled Attachments

The "Flying Saucer"

Details the 'Flying Saucer' attachment: a 2-in-1 hold-down and cam clamp for securing material.

Universal Corner Stop / Cam Clamp

Describes the Universal Corner Stop/Cam Clamp, offering two points of contact for odd shapes.

360 Hold-Down Fence

Features of the 360 Hold-Down Fence: rotates, locks at any angle, acts as fence or hold-down.

Sliding Fence Stops

Details on Sliding Fence Stops: locks anywhere, reversible, used as hold-down for thin material.

Box Joint Jig

Information on the Box Joint Jig for easy alignment, using kerf keys and spacers for precise cuts.

Vertical Cutting Jig

The Vertical Cutting Jig provides a 90-degree wall for vertical cuts and attaches via MATCHFIT hardware.

Miter Attachment

The Miter Attachment is a 45-degree template for precise angle cuts, attaching with MATCHFIT hardware.