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

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

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