Wedge-Pro Sleds & Material Stop Instruction Manual

Instruction manual

Wedge-Pro® Sleds & Material Stop

These instructions cover setup, adjustment, and basic use for the Wedge-Pro®, Wedge-Pro® II, Wedge-Pro-PL, and the Wedge-Pro® Material Stop.

  • Wedge-Pro®
  • Wedge-Pro® II
  • Wedge-Pro-PL
  • Material Stop
Always read and understand these instructions before using the Wedge-Pro system. Table saws are dangerous tools. You are responsible for safe operation, proper setup, and safe cutting practices.
Blade-side configuration: The original Wedge-Pro® is the only reversible sled and may be configured for either the left or right side of the blade. Wedge-Pro® II and Wedge-Pro-PL sleds must be installed on the left side of the blade. The Wedge-Pro® Material Stop may be configured on either side of the blade.
Safety FirstSetup GuidePrepare the SledMaterial StopUsing the SledTest RingTroubleshooting

1. Safety First

  • Always wear eye protection.
  • Keep the table saw blade height as low as practical for the cut.
  • Only place your hands on the provided handles while cutting.
  • Never place your hands near the blade path or the front exit point of the sled.
  • Do not use the table saw ripping fence with the Wedge-Pro sled during segmented cutting.
  • Use push sticks and safe workholding practices when cutting small strips or small parts.
  • Do not modify the sled, fence, clamp, handle, sweeper, material stop, or miter bar system.
  • Before using the product, make sure you are confident using your table saw.

2. Prepare the Setup Guide

  1. Place the setup guide into the miter slot that matches your sled configuration: either side of the blade for the original Wedge-Pro®, or the left side of the blade for Wedge-Pro® II and Wedge-Pro-PL.
  2. Wiggle the setup guide gently and adjust the two leveling screws until the guide is firmly seated with no side-to-side movement.
  3. Verify that your table saw blade is set to 90°.
  4. Raise the blade approximately 3/4″.
  5. Slowly make the indexing cut in the setup guide. Keep one hand firmly on top of the guide with your fingers between the two leveling screws.
  6. Turn off the saw and lower the blade below the table surface.
Setup guide seated in the table saw miter slot near the blade for the indexing cut
Setup guide positioned in the miter slot for the indexing cut. Keep the guide seated firmly while making this cut.
The setup guide must not wiggle side to side. This setup step establishes the sled’s relationship to the miter slot.

3. Prepare the Sled

  1. Adjust the brass grub screws on the miter bar with the included 3/32″ Allen wrench so the miter bar slides smoothly without side-to-side play.
  2. If the phenolic miter bar must be trimmed to fit your saw, remove the brass grub screws before cutting the bar to size. The miter bar is designed for standard 3/4″ (19 mm) miter slots. Some European saws use 5/8″ (about 16 mm) miter slots; when trimming for a slot this narrow, split the material removal evenly between both sides of the bar, about 1.6 mm per side. Do not remove all of the material from one side because this can leave the mounting holes too close to the edge and compromise the miter bar.
  3. Loosely attach the miter bar to the underside of the sled using the supplied 1/4″ x 3/4″ slotted sidewalk bolts. Do not fully tighten yet.
  4. Make sure the setup guide is still firmly seated in the miter slot, then place the sled and miter bar into the miter slot.
  5. Wedge-Pro® and Wedge-Pro® II: carefully align the 1/8″ kerf notch on the sled with the indexing cut in the setup guide. Wedge-Pro-PL: the Wedge-Pro-PL does not have a kerf notch. Position the sled so it just misses the blade; the blade should not contact the sled.
  6. Once aligned, firmly tighten the two miter bar bolts.
  7. Set the setup guide aside, but do not discard it. You may need it for future adjustments.
Wedge-Pro sled placed on a table saw with the fence, handle, clamp, index pins, and miter bar visible
Set the sled and miter bar into the miter slot, align the sled, then tighten the miter bar bolts.
Close-up of the Wedge-Pro sled kerf notch aligned with the setup guide indexing cut
For Wedge-Pro and Wedge-Pro II models, align the sled kerf notch with the setup guide indexing cut before tightening the miter bar bolts. For Wedge-Pro-PL, position the sled so it just misses the blade.
The sled should be set perpendicular to the miter slot. The blade relationship is secondary because the sled travels in the miter slot.
Make sure the setup guide does not wiggle during alignment or while tightening the miter bar bolts.

Two-Fence Sled Note

Two-fence sleds, such as the Wedge-Pro® II and Wedge-Pro-PL, have built-in error correction because the opposing fences cut matching complementary angles. The sled still benefits from the same careful setup process. If the second fence is removed later and the sled is used as a single-fence cutting jig, any setup error that was previously being corrected by the opposing fences may show up as gaps in the ring.

Best practice: set up every Wedge-Pro sled accurately from the beginning, even if you normally plan to use both opposing fences.

4. Make the Zero-Clearance Cut (Wedge-Pro and Wedge-Pro II Only)

This section does not apply to the Wedge-Pro-PL. Do not cut through the Wedge-Pro-PL on the table saw; it does not have a zero-clearance strip and does not require a zero-clearance cut.
  1. For Wedge-Pro and Wedge-Pro II sleds only, position the sled away from the blade.
  2. For Wedge-Pro and Wedge-Pro II sleds, raise the blade high enough to cut through the sled body. For the standard setup, raise the blade to make approximately a 2-1/2″ cut.
  3. With both hands on the provided handles, slowly push the Wedge-Pro or Wedge-Pro II sled through the blade.
  4. For those models, continue the cut fully through the sled from back to front.
Wedge-Pro sled making the zero-clearance cut through the sled body on a table saw
Zero-clearance cut through the sled body. Keep both hands on the handles and stay clear of the front blade exit path.
If future sled adjustments enlarge the zero-clearance cut, that is okay. The purpose of this cut is to leave the chamfer strip in place so the cut segment is directed away from the blade, the sweeper is supported, and the segment has bottom support while it is being cut.
For Wedge-Pro and Wedge-Pro II sleds, be aware that the blade exits the front of the sled. Keep hands on the handles only.

5. Install the Sweeper

  1. Remove the sweeper from its shipping position.
  2. Attach it to the rear attachment point of the sled, closest to the back of the table saw, using the supplied 1/4″ x 3/4″ button head screw.
  3. Verify that the sweeper clears the blade path and moves safely with the sled.
Black sweeper installed at the rear attachment point of the Wedge-Pro sled
Sweeper installed at the rear of the sled with the attachment screw visible.

6. Prepare the Material Stop

  1. Make sure the adjustable fence is fully seated on the material stop base.
  2. Place the material stop in the miter slot opposite the sled. The material stop may be configured on either side of the blade.
  3. Slide the material stop until the 0 inch and 0 cm marks are both aligned with the edge of the bridge, then tighten the adjustment knob.
  4. Position the material stop so it slightly overhangs the blade area.
  5. Before tightening the mounting screws, use the setup guide as shown in the second photo to set the material stop perpendicular to the blade.
  6. Secure the material stop miter bar using the supplied 1/4″ x 3/4″ slotted sidewalk bolts.
  7. Slowly make the indexing cut in the material stop while keeping one hand firmly on top of the material stop.
Wedge-Pro material stop positioned over the blade area with the adjustment scale and bearing visible
Material stop positioned over the blade area for the indexing cut, with the scale and adjustment knob visible.
Material stop aligned perpendicular to the blade with the setup guide before tightening the mounting screws
Use the setup guide as shown to set the material stop perpendicular to the blade before tightening the mounting screws.

7. Using the Wedge-Pro Sled

  1. Remove the table saw ripping fence. It is not used for segmented cutting with the sled.
  2. Set the Wedge-Pro fence for the desired number of segments by placing the supplied indexing pin in the corresponding segment-count hole. Depending on your version, the indexing pins may be 5 mm or 3 mm.
  3. Tighten the fence using the adjustment knob while verifying that the fence is placed firmly against the central pivot pin and the selected segment-count pin.
  4. Place the prepared strip in front of the fence and secure it using the spring clamp.
  5. Make the cut with hands on the sled handles only.
  6. After each cut, rotate or flip the strip 180° to cut the opposing miter.
Index pin check: when using the index pins, the pins must stay fully seated and in place through setup, adjustment, and use. Before tightening the fence and before cutting, double check that the fence is tight against the central pivot pin and the selected segment-count pin. If a pin lifts, shifts, or is removed, stop and reset the fence before making a cut.
For accurate segmented rings, both opposing faces of the strip must be parallel. If the strip is not parallel, the ring may not close properly even if the sled is set correctly.

8. Using the Material Stop

For Segmented Cutting

Place the material stop in the miter slot opposite the sled. Loosen the adjustment knob, set the desired segment length by measuring at the base of the stop close to the bearing, then tighten the adjustment knob. Use consistent pressure against the stop so segment lengths remain repeatable.

For Thin Ripping

The Wedge-Pro Material Stop can also be used as a thin-rip guide. In this setup, the bearing allows the keeper strip to be cut without being trapped between the blade and the table saw fence.

  1. Place the material stop in the miter slot opposite the table saw ripping fence.
  2. Point the material stop away from the fence.
  3. Set the gap between the bearing and the side of the blade to the desired strip width.
  4. Move the material stop approximately 6″ in front of the blade and tighten it securely.
  5. Place the material against the bearing.
  6. Bring the table saw fence to the opposite side of the material.
  7. After each cut, move the fence closer to the material stop for the next strip.

9. Cut a First Test Ring

Before beginning a project, cut a simple test ring to confirm setup accuracy.

  1. Set the sled for 8 segments.
  2. Set the material stop for approximately 1-1/2″ segment length.
  3. Cut 8 test segments from a straight, parallel strip.
  4. Assemble the ring and check the inside and outside joints.
When testing a Wedge-Pro® II or another two-fence sled, use one fence only for the test ring. After each cut, flip the strip and continue cutting.

10. Adjusting and Troubleshooting Ring Gaps

The Wedge-Pro sled may require a minor one-time adjustment to dial in the fence so it is perpendicular to the miter slot. The blade relationship to the fence does not matter; the setup is controlled by the miter slot.

Before diagnosing the cut: align the test segments consistently around the ring. If a segment sits in or out, the joint should show a parallel gap; that is an alignment issue, not a cutting error. A test ring may fail to close if the segments are not aligned consistently, even when the segments were cut correctly.
  1. If the test ring is tight, no adjustment is necessary.
  2. If the test ring has small gaps, place paper shims between the setup guide and the sled, then retighten the bolts securing the miter bar.
  3. Start with 5 pieces of printer paper as shims. A single sheet may not create enough visible change.
  4. If the gaps are on the inside of the ring, shim the left side of the sled and retest.
  5. If the gaps are on the outside of the ring, shim the right side of the sled and retest.
  6. After shimming, cut another test ring. If the gaps are larger, move the shims to the opposite side. If the gaps are smaller, add more shims on the same side and continue as needed.
Paper shims placed between the setup guide and Wedge-Pro sled during alignment adjustment
Paper shims go between the setup guide and sled. Shown on the left side; use the same placement on the right side when correcting outside ring gaps.
Problem Likely Cause Correction
Ring closes tightly Setup is accurate No adjustment needed
Gaps appear on the inside of the ring Sled alignment needs correction Shim the left side of the sled/setup guide relationship and retest
Gaps appear on the outside of the ring Sled alignment needs correction Shim the right side of the sled/setup guide relationship and retest
Segment lengths vary Material stop moved or strip was not seated consistently Retighten the material stop and use consistent pressure against the stop
Parallel gap appears when one segment is in or out Segments are not aligned consistently around the test ring Realign the segments evenly before judging the cut. A parallel gap from a shifted segment is not a cutting error.
Ring will not close consistently Material strip may not have parallel faces Joint or prepare the strip so both long faces are parallel before cutting
Test ring showing gaps on the inside joints
Inside ring gaps: shim the left side of the sled/setup guide relationship and retest.
Test ring showing a gap on the outside joint
Outside ring gaps: shim the right side of the sled/setup guide relationship and retest.
The old printed examples used exaggerated shim stacks to make the gap direction obvious. Use only the amount of shim needed to correct your sled.

11. Final Safety Reminders

  • You assume all risk and responsibility for the proper and safe use of this product.
  • Anyone using this product should read and understand these instructions first.
  • Sharp tools are safer tools. You should never have to force a cut.
  • The miter bar must be installed for the sled to function properly.
  • The table saw ripping fence is not used in conjunction with the sled during segmented cutting.
  • Hands should only be placed on the designated handles while cutting.

Revised July 29, 2026