Well.... I thought this previous sled was everything I ever needed..
Well...... it turns out there were some further options that I wanted / needed, so I made this newest version a couple weeks ago.
I'm still using a ZCI system that I incorporated in to the last one. Being able to use the sled for dado cuts has been very handy. I have inserts for 1/8", 1/2", and 3/4". The only problem I had was some tearout on the exit end of the piece. After making a dado cut - the fence no longer had a zero clearance. In this new sled, I made a split fence system that allows me to adjust for blade thickness as well. You can see in this pic, the 1/2" dado insert is installed and the fence is set acordingly.
I also began to cut through the safetyblock of my old sled. Those small bumps of the blade add up after time and finally penetrate the block. With it glued on, there was little to do except cut it off and apply a new one. Now, I've gone to an adjustable block. If I start to cut through it, I can slide it over to a fresh spot. Once it's all worn out, I can simply remove it and make a new one to slip on.
Also..... not wanting to make a HUGE sled that took up a bunch of room and weighed a ton, I usually keep the stop block at about 24" max cut. Finding myself wishing for wider cutting capabilities I also added a telescoping stop block system to this new one.. I now have standard 24" to the left of the blade or anywhere up to 36" with the stop block extended. A simple allen bolt through the top of the fence locks the telescoping fence in place.
The last upgrade I made was to add a removable miter fence. I have an incra 3000 so I'm not trying to add a precision miter or anything, but for irregular pieces or when I want to make sure the cutoff stays put - this attachment should come in handy. Simple enough to add, I burried a threaded insert under the formica for one end, and a T slot cutter with circle jig made a nice track for the other end.
Finally...... here's a couple over all shots. Thanks for taking a look.