Woodhaven 4965 Super Sled User manual

Part Desc. . . . . . . . . . . . . . . . . . . . . . . . . Qty
4924B 24" Jig Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4965A 32" Fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4965B Sled Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4965C Fence Brackets, Pair. . . . . . . . . . . . . . . . . . . . . . . . 1
4965D Track Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6305A Outboard Clamp Bracket . . . . . . . . . . . . . . . . . . . 2
6305IC Inboard Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4519 Straight Flip Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Parts List
4965 Super Sled
Owners Manual
Please Read Carefully!
Part# Description Qty.
5760B Oval Nut 5
Part# Description Qty.
HB030 1" Bolt 3
Part# Description Qty.
BUSH004 5/8" Spacer 1
Part# Description Qty.
WS002 Washer 6
BEFORE BEGINNING
Identify and verify that you have all the parts listed in
the parts list above, plus the parts shown on this page. Read
through the instructions at least once before beginning. You'll
need a #2 & #3 Phillips screwdriver for assembly.
The Super Sled is designed to be used on a table saw at
least a 27" deep with a 3/8" x 3/4" miter slot that's between
4-1/2" and 7-1/2" from the blade, measured from the blade
side edge of the slot. It can be used in the left or right miter
slot. Do not attempt to use on table saws with tables smaller
than 27". If necessary, add additional supports to your saw to
prevent the saw from tipping.
For the Super Sled to work properly, the miter slot of
your saw must be parallel to the saw blade. If this is not the
case, make those adjustments to your saw before proceeding.
Part# Description Qty.
BUSH001 1/8” Spacer 2
Part# Description Qty.
5590 Knob 1
Part# Description Qty.
MF006 5/8" Screw 4
Part# Description Qty.
NUT025 Square Nut 4
Part# Description Qty.
5864 Ratchet Handle 2
Part# Description Qty.
5540 T-Knob 2
Part# Description Qty.
BUSH002 1/4" Spacer 2
Part# Description Qty.
4965PA Index Pin 2
Part# Description Qty.
5505 Thumb Screw 1
Part# Description Qty.
MP150 1-1/2" Screw 2

1
Crosscut Setup:
The Super Sled rides in the miter slot of the saw. Follow the instructions that come with
the Jig Bar (4924B), install the hardware in the bar and adjust the bar to fit the left or right miter
slot you've elected to use. These directions show the left miter slot being used.
Lower the saw blade below the saw table. Place the Jig Bar, with the countersunk holes facing down, in the miter slot.
There are two sets of bar mounting holes in the Sled Base (4965B). One set is for crosscut work (Slots in Sled Base are
parallel to miter slot.) and the other set is for taper work (Slots in Sled Base are square to miter slot.). See fig. 1 & 2
Setup for crosscut work: Align the crosscut bar mounting holes in the Sled Base with the threaded holes in the Jig Bar,
positioning the Sled Base over the bar so that it doesn't overhang the cutting path of the saw blade by more than 1/2". Attach the
Jig Bar to the Sled Base with the 1" flat head screws (MF010) included in the 4924B hardware. After mounting the Jig Bar to
the Sled Base, recheck the fit of the Jig Bar in the miter slot, making sure it slides smoothly but without slop.
Raise the blade, turn the saw on and cut off the crosscut edge of the base overhanging the
saw blade (This should be no more than 1/2"!), guiding the bar/base assembly in the miter slot.
Turn the saw off, disconnect the power and lower the blade below the saw table.
MF010 x4
MF010 x4
4965B Sled Base - Taper Setup
Slots in Base at 90º to blade
4965B Sled Base - Crosscut Setup
Slots in Base parallel to blade
Taper Setup:
Lower the saw blade below the saw table. Place the Jig Bar, with the countersunk holes facing down, in the miter slot.
There are two sets of bar mounting holes in the Sled Base (4965B). One set is for crosscut work (Slots in Sled Base are
parallel to miter slot.) and the other set is for taper work (Slots in Sled Base are square to miter slot.). See fig. 1 & 2
Align the taper bar mounting holes in the Sled Base with the threaded holes in the Jig Bar, positioning the Sled
Base over the bar so that it doesn't overhang the cutting path of the saw blade by more than 1/2". Attach the Jig
Bar to the Sled Base with the 1" flat head screws (MF010, in the 4924B hardware). After mounting the Jig Bar to
the Sled Base, recheck the fit of the Jig Bar in the miter slot, making sure it slides smoothly but without slop.
Raise the blade, turn the saw on and cut off the crosscut edge of the base overhanging the
saw blade (This should be no more than 1/2"!), guiding the bar/base assembly in the miter slot.
Turn the saw off, disconnect the power and lower the blade below the saw table.
When switching between crosscut and taper setups, leave the bar in the
miter slot to insure it's always remounted in its original position.
1
2

2
FENCE BRACKET ASSEMBLY
The vertical fence configuration is normally used for
crosscuts. Insert two 5/8" screws (MF006) thru the countersink
holes in the Fence Brackets (4965C) and start an oval nut
(5760B - flat side first) on the end of each screw. Slide the
Fence Brackets on to the T-slot in the edge of each Track Bracket
(4965D), position the narrow end of the Fence Bracket even with
the end of the Track Bracket and tighten the screws. See fig. 3
Install a washer (WS002) and a 1/8" spacer (BUSH001) on
the ratchet handles (5864). Insert the stud of the ratchet handle
thru the hole of the Track Bracket. Set each Track Bracket on
the Sled base so the wide end of the Fence Brackets are towards
each other. Insert the stud of the ratchet handle thru the slot in
the Sled Base. Place a square nut (NUT025) in the recess in the
underside of the Sled Base and screw the ratchet handle into the
nut. See fig. 3-4
3
MF006 x2 HB030
WS002
5540
5864
WS002
BUSH001
4965D
4965C
5760B x2
4
NUT025
Fence Bracket
Assembly
4965B
Sled Base
4965A
Fence
Crosscut Fence Setup:
The vertical fence configuration is normally used for crosscuts. Insert a 1" bolt (HB030) thru
the hole in each of the Fence Brackets, install a washer (WS002) and a knob (5540) on the end of each
bolt. Slide the the 32" Fence (4965A) on to the bold heads and tighten the knobs. Assemble the Flip Stop
(4519) according to the directions that come with it and attach it to the top T-slot of the Fence.
See fig. 3-4
INSTALL INBOARD CLAMPS
Assemble the two Inboard Clamps (6305IC) according to the directions that come with them and attach each to an
Outboard Clamp Bracket (6305A). Insert a washer (WS002) on the 1-1/2" screws (MP150), insert the screw thru the hole in the
Outboard Clamp Bracket, place a square nut (NUT025) in the recess in each slot in the underside of the Sled Base and tighten
the screw into the nut.
5
Clamp
Assembly
Fence Brackets
4965A
Fence
4519
Flip Stop

3
FENCE INSTALL FOR TAPERS
The horizontal fence configuration is normally used for tapers. Install a washer (WS002) and a 1/8"
spacer (BUSH001) on the ratchet handles (5864). Align the slots in the 32" Fence (4965A) with the slots in
the Sled Base. Insert the stud of the ratchet handle thru the slot of the Fence and the Sled Base. Place a square
nut (NUT025) in the recess in the underside of the Sled Base and screw the handle into the nut. See fig. 6
Insert a 1" bolt (HB030) in the desired T-slot in the Fence, then a 5/8" spacer (BUSH004) and a handle
(5590) on the end of the bolt. Position the handle where desired on the Fence and tighten. See fig. 6
Insert two 1/4" spacers (BUSH002) on a thumb screw (5505) and start an oval nut (5760B - raised
side first) on the end of the thumb screw. Slide it on to the T-slot on the edge of the fence, position it
near the end of the fence for now and tighten. This will serve as a work Stop. See fig. 6 inset
Assemble the two Inboard Clamps (6305IC) according to the directions that come with
them and attach them to the front or center T-Slot of the Fence. See fig. 6
6
Fence Knobs x2:
5864
WS002
BUSH001
NUT025
Handle:
5590
BUSH004
HB030
Clamp
Assembly
4965B
Sled Base
4965A
Fence
Work Stop:
5505
BUSH002 x2
5760B
Taper Setup - Horizontal - Example 1:

SLED OPERATION:
Be sure to observe all safety precautions when using the table saw. The cut-off from your work can be thrown by the
table saw blade as it falls to the table. To help prevent this, clamp a 3/4" thick board on the opposite side of the blade.
By placing the Index Pins (4965PA) in the appropriate indexing holes engraved in the Sled Base, you can
set Fence angles of: 0º, 15º (12 sides), 22-1/2º (8 sides), 30º (6 sides), 36º (5 sides) & 45º (4 sides). There are
non-engraved indexing holes directly opposite the engraved indexing holes that are the same angle, only in
the opposite direction. If necessary, a spacer (supplied by you) can be placed between the pins and the fence
to place the fence in a better position. In addition, there are four holes that serve as parking spots for the Index
Pins. Other angles can be set using our optional 3690 Mite-R-Gage or a similar device. See fig. 7
The fence can be used at the rear of the work (fence closest to operator, shown in drawings) or
in front of the work (fence furthest away from operator, not shown). In both cases the toggle clamps/
brackets should be positioned opposite the fence, with the work between the fence and clamps.
4
7
Crosscut Fence Setup - Vertical - Example 1:
The vertical fence configuration is normally used for crosscuts. To set the angles with the Index Pins, place
them in the desired locations behind the vertical fence, index the fence against them and tighten the handles.
Crosscut Fence Setup - Vertical - Example 2:
The vertical fence configuration is normally used for crosscuts. To set the angles with the Index Pins, place
them in the desired locations behind the vertical fence, index the fence against them and tighten the handles.
4965PA
4965PA
4965PA
4965PA
Fence at 0º
Fence at 0º'
Fence at 45º
Fence at 45º
Vertical Fence 0º Vertical Fence 45º

5
SLED OPERATION CONTINUED:
7
Crosscut Fence Setup - Horizontal - Example 1:
The horizontal fence configuration can be used for crosscuts, but is not recommend, etc. To set the angles with the Index
Pins, place them in the desired locations in front of the horizontal fence, index the fence against them and tighten the handles.
Crosscut Fence Setup - Horizontal - Example 2:
The horizontal fence configuration can be used for crosscuts, but is not recommend, etc. To set the angles with the Index
Pins, place them in the desired locations in front of the horizontal fence, index the fence against them and tighten the handles.
Fence at 0º'
Fence at 0º'
Optional 789S
Flip Stop
Fence at 45º
Fence at 45º
4965PA
4965PA
4965PA
4965PA
Horizontal Fence 0º Horizontal Fence 45º
Optional 789S
Flip Stop

USING THE SUPER SLED FOR CROSSCUTS
After setting the Fence angle, place the work on the Sled Base, butted against the Fence and the Flip Stop. Slide the
Outboard Clamp Brackets/Toggle Clamps against the opposite side of the work. Tighten the Outboard Clamp Brackets to the
Sled Base, then tighten the Toggle Clamps on the work using medium pressure. Do not over tighten! Make the cut, being sure
that the work is not touching the blade before starting the cut.
8
6
Crosscut Fence Setup - Vertical

OPTIONALACCESSORIES
The 6305R Riser Kit increases the capacity of the toggle clamps to 2-3/4" thick stock.
The 3690 Mite-R-Gage is a handy tool for setting odd angles not covered by the indexing holes in the Super Sled. The 789S
Flip Stop is available for use with the Horizontal fence.
©Copyright WOODHAVEN INC. 9/25/12
[phone] or WWW.WOODHAVEN.COM
7
USING THE SUPER SLED FOR TAPERS
Set the Fence to the desired taper or angle. This is done by lining up the cut lines on your
work with the cut edge of the Sled Base, which is also the cut line of your saw. Position the fence
against the opposite side of the work and tighten. Adjust the Stop against the end of the work.
Position the handle and toggle clamps on the Fence where desired. Tighten the toggle clamps on the work using medium
pressure. Do not over tighten! Make the cut, being sure that the work is not touching the blade before starting the cut.
9
789S Flip Stop3690 Mite-R-Gage