Cut-Off Sled for Side Rails
To build this sled, start with a piece of 3/4-in. plywood cut to 19-1/4-in. wide by 30-in. long. On this piece of plywood, lay out the 25-degree angle that will go against the tablesaw rip fence. Rough cut this angle with your bandsaw or jigsaw. True it up with a router and straightedge. Then, set your tablesaw to 18-1/2 in. and cut the other 25-degree angle. Add the 1/2-in. MDF spacer on top and the toggle clamps and you're ready to go.
Cut a couple extra rails (C, D and E) out of scrap wood to use later for testing your tenon-cutting setup.
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