How to Make a Sled for Cutting Thin or Odd-Shaped Stock

Thin, flexible, or oddly shaped workpieces can't be clamped conventionally. A custom sled — a sacrificial carrier — holds them securely at a consistent height.

When You Need a Sled

• Veneer or thin sheet under 6mm (flexes, tape isn't enough)
• Round or irregular shape with no flat clamping surface
• Pieces already cut to shape needing secondary operations
• Resawned slabs that aren't flat on the bottom

Making a Flat Sled

1. Cut a piece of MDF to slightly larger than your workpiece
2. Surface the MDF with the CNC to guarantee flatness
3. Apply double-sided tape to the top
4. Press workpiece onto tape firmly
5. Mount the sled (not the workpiece) with clamps
6. Zero Z to the workpiece surface, not the sled

The sled absorbs the clamp pressure and keeps the thin workpiece flat.

Contoured/Pocket Sled

For curved or irregular bottom surfaces:

1. Machine a pocket into MDF that matches the workpiece bottom shape
2. Press the workpiece into the pocket — it can't shift
3. Add tape or side stops for extra security

Vacuum Sled (No Pump Needed — Tape Method)

1. Drill a grid of small holes (2mm) through an MDF sled
2. Place workpiece over holes
3. Apply tape around perimeter to create a seal
4. Drill a single port hole
5. Use a shop vac connected to the port — vacuum holds the piece

This works surprisingly well for flat sheet goods.

Key Tips

• Sled must be surfaced after mounting — the mounting can flex it slightly
• For repeat production: make the sled once, reuse it
• Mark the sled clearly with material and project name
• Toss when cut through too many times or warped