microjig ZEROPLAY User manual

ZEROPLAY Miter Bar 2-Pack Project Plans

1
This table saw sled combines the ease and precision of ZEROPLAY Miter Bars with the versatil-
ity of the MATCHFIT System. Its modular design allows the user to add a variety of attach-
ments for a wide array of functions. Its defining feature is the incorporation of interchangeable
zero-clearance inserts. Each insert is dedicated to one blade, set at one angle. This ensures
tearout-free cuts, no matter the blade or angle of cut, all with just one sled.
- ZEROPLAY Miter Bars Double Pack (ZP9-B2S2)
- (2) MATCHFIT Dovetail Hardware Variety Packs
- 1/2”, 14-degree dovetail router bit
- 1/4” diameter straight or spiral router bit
- 1/2” diameter forstner bit
- 3/8” diameter forstner bit
- 1/4” diameter standard drill bit
- Flush trim router bit
- Table saw
- Router table or handheld router with edge guide
- Flat carpenters triangle
- Double-sided tape
- (1) 20” x 30“, 1/2” thick plywood (PART A)
*
void-free recommended
- (1) 1-1/2
”
thick, 2“W x 30”L hard maple (PART D)
-(2) 12-1/8 x 20-1/4, 1/2” thick plywood
(PARTS B & C)
- (1) 1-1/2
”
thick, 2“W x 6”L hard maple (PART E)
-(6) 24
“
x 6
”
, 1/2” thick plywood (PARTS Z1-Z6)
(A)
(B) (C)
(Z1)
(D)
(E)

PART A
PART B PART C
PART D
PART E
PART Z1

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* NOTE: Cut all plywood parts from the same sheet to ensure uniform thickness.
On the table saw, cut a sheet of 1/2” thick, void-free plywood down to 20” x 30”.
This will be the base layer of the sled (PART A).
Next, cut two pieces of 1/2” thick, void-free plywood down to 12-1/8” x 20-1/4”.
These will be the left and right wings of the top layer of the sled (PARTS B & C).

Next, cut (six) 6” wide x 24“ long strips of 1/2” thick, void-free plywood. These will
be the interchangeable zero-clearance inserts (PARTS Z1-Z6).
Z1
1/8” kerf
@ 90 degrees
1/8” kerf
@ 45 degrees
thin kerf
@ 90 degrees
thin kerf
@ 45 degrees
3/8” dado
@ 90 degrees
1/4” dado
@ 90 degrees
Z2 Z3 Z4 Z5 Z6
3
CONTINUED

Prepare a solid piece of hard maple (or other dense hardwood) to finish at 1-½”
thick x 2” wide x 30” long. This will be the fixed rear fence of the sled (PART D).
Cut an additional solid piece of hard
maple to finish at 1-½” thick x 2” wide
x 6” long. This will be the center sup-
port of the fence, keeping the two
sides of the sled together after the
first cut (PART E).
4
CONTINUED

STEP 2 - CUT DOVETAIL TRACKS FOR ZERO-CLEARANCE INSERTS

7
12”
BC
Z1
12”
Thread on the screws and Dovetail Track Nuts in the Dovetail Hardware Variety Pack
to the bottom of the zero-clearance insert (PART Z1), then insert the Dovetail Track
Nuts in the dovetail tracks in the base layer of the sled (PART A)
Use a square to make sure that the
zero-clearance insert is square and
centered on the sled base with
exactly 12” on each side. Once
square and centered, tighten the
Dovetail Hardware.
Apply glue to the base layer on both
sides of the zero-clearance insert.
Place PARTS B & C on top of PART A,
flush with the edge of the zero-clear-
ance insert. Clamp down using cauls
to distribute pressure evenly.
STEP 4 - ASSEMBLE SLED PARTS

8
ZCI removed
You’ll notice that the wings are slightly oversized. Make sure that the wings
overhang the base evenly on all three exposed sides.
Once PARTS B & C are clamped in place, loosen the screws and remove the
zero-clearance insert to prevent the squeeze out from permanently gluing it in
place.
Allow enough time for the glue to dry according to the manufacturer’s instructions.
While the glue is drying, proceed to the next step.
STEP 4 - ASSEMBLE SLED PARTS CONTINUED