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The "I'm Not Worthy" Project Log #7: Cross Cut Sled - Winging It!!!

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Blog entry by DIYaholic posted 150 days ago 992 reads 1 time favorited 22 comments Add to Favorites Watch
« Part 6: Zero Clearance.... Not NSA Approved!!! Part 7 of The "I'm Not Worthy" Project Log series Part 8: I Said Hold Down for a Jig.... Not a Jig at a Hoe Down!!! »

Besides motivation, energy and time….
I need a cross cut sled.

I’ve checked out most of the various sleds and “Super” sleds here on LJs, from the basic to the multifunction/multipurpose sleds. All these possibilities led to a paralysis by analysis situation. Since I was worried about how accurate my “first” sled would be, I decided not to over complicate things by making a “super sled”. I figured why put so much effort into something I wasn’t sure would be a “keeper”!!! The plan was to make a small sled, that would serve me well and take what I learn in the build and apply that knowledge into a future “Super Sled”.

Like I usually do….
I’ll let the pictures tell (most of) the story….

I had some 1/2” Birch Ply (from that Big Blue store) that I would use for the sub-base of the sled. Affixed on top of that would be repurposed Bamboo engineered flooring, for the “work surface” of the sled. Since I hate seeing the ply edge on anything, all of this would be edge banded in repurposed oak flooring. No good pictures of the base build, wasn’t taking many pictures as I just wanted to “Git ‘er done”....

I needed to route a few grooves for some T-Track.
Especially since I have about 16’, yes FEET, of Inca T-Track collecting dust….
I calculated the spacing in a very analytical way….
I placed the grooves in the T&G joint of the flooring.

I later added a fourth T-Track on the very right edge.
I figured it would be easier to add it now, if ever needed, than after the sled was completed.

Runners: On your mark, set, GO!!!

Would you believe that I used repurposed oak flooring for the runners???
Glued and screwed….

With the base of the sled sliding easily and without slop, it was time to focus upon the rear and main fence.
Lumber prep:

You guessed it….
Both of the fences were glued up from repurposed oak flooring.
Hey, I have a lot of it.
After the glue-up, the fence blanks were jointed and planed

Then the main fence was routed for T-tracks….

With the rear fence installed, it was time to attach the main fence.
I followed the William Ng 5-Cut Method video tutorial for the alignment.
However, I must first (re) align the blade to the miter slots.
I think I got it as close to perfect as I could….

Dial Indicator measurement at front of blade:

Dial Indicator measurement at rear of blade:

Is that “close enough for g’ument work”???

Time for the 5-Cut Method of fence alignment:

I did the “alignment” three times and then gave up….
When I did the calculations, I kept getting an exponent!!!
I’m either right on or waaaaaay off!!!

Now that the main fence was installed…
To prevent “slippage”, I added sandpaper to the face of the main fence.

More of that 16’ of dust collecting T-Track was installed.
I made sure to leave clearance for any future blade misalignment.

T-Track and any hope for repeatability would all be for naught….

Overall the sled can cross cut a 13”+ wide board.
Good thing as that just happens to be the width of my DeWalt 735 Planer!!!
The main fence can handle a board up to 24”+...
more without the repeatability of the stop block.

I still need to fabricate the “blade guard box” for the main fence and fashion some hold downs.

Here it is, made on a wing and a prayer….

It may not technically qualify, But to me….
This is a SUPER Sled!!!

Thanks, for taking the time to view and read….

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?



22 comments so far

View gfadvm's profile

gfadvm

10533 posts in 1286 days


#1 posted 150 days ago

Holy Cow Randy! You really outdid yourself on this one! That is WAY fancier than my “Super Sled”.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View Gary's profile

Gary

6963 posts in 2029 days


#2 posted 150 days ago

Nice work, Randy. Looks like a pro job

-- Gary, DeKalb Texas only 4 miles from the mill

View JL7's profile

JL7

6978 posts in 1561 days


#3 posted 150 days ago

Randy, this is WAY to fancy to subject to saw dust…....really man…..WOW. You could break this out along with the fine china when entertaining…...

So what are you saying about the 5-cut thing? You just abandoned it?

I used re-purposed flooring on mine as well, so I think that is GREAT idea….....

What kind of cross cut blade you got there? Looks pretty sporty….

Keep us posted on the additions you make….seems like a pretty versatile platform for the long haul. Well done!

BTW….I burned the Jiffy Pop and now the house stinks…....crap.

-- Jeff - I have not failed. I've just found 10,002 ways that won't work.

View lightcs1776's profile

lightcs1776

3263 posts in 250 days


#4 posted 150 days ago

You really shined on that project. That could be marketed on Rockler. Excellent job.

-- Chris ** If there must be trouble, let it be in my day, that my child may have peace. — Tom Paine **

View DIYaholic's profile

DIYaholic

12860 posts in 1271 days


#5 posted 150 days ago

Thanks Andy.
Fancy or not, I just want it to be accurate and easy to use.

Gary,
Thanks for the kudos.
Glad you are feeling better!!!

Jeff,
I only used repurposed materials and scraps. It is what it is….
I didn’t abandoned the 5-Cut method….
I just got it as close as I could and wasn’t worried about perfection.
(.0015” over 19”)

I’m going to revisit the accuracy calculations, once my brain comes out of the fog!!!

My arsenal of TS blades are all “Irwin Marbles Woodworker Series”....
Crosscut,
Rip,
Combination,
Laminate & Ply.

I have two CC blades, one for the TS and another for the SCMS.

Thanks, everyone!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View DIYaholic's profile

DIYaholic

12860 posts in 1271 days


#6 posted 150 days ago

Chris,
Thanks for the accolades.
I’m not sure about Rockler….
Harbor Freight on the other hand!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View JL7's profile

JL7

6978 posts in 1561 days


#7 posted 150 days ago

Good info thanks…..I love the re-purposed materials and was just funnin’ ya. I believe if it’s worth building, then it’s worth building well…...you got it here…..

-- Jeff - I have not failed. I've just found 10,002 ways that won't work.

View DIYaholic's profile

DIYaholic

12860 posts in 1271 days


#8 posted 150 days ago

Jeff,
I may not build it well, but I can build it purty!!!
I actually purchased the bamboo flooring with jigs & sleds in mind.
Might as well have good looking stuff…
Even if accuracy & functionality may be suspect!!! ;^)

I appreciate the kind words, thanks!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View Mainiac Matt 's profile

Mainiac Matt

3830 posts in 924 days


#9 posted 150 days ago

Nice job Randy….

I found squaring the fence to be the hardest part and the 5 cut method nearly drove me insane….

-- Pine is fine, but Oak's no joke!

View eddie's profile

eddie

6967 posts in 1210 days


#10 posted 150 days ago

Randy great Cross Cut Sled ,and thanks for sharing to lot of info on the build too, great job all the way around and your shop is looking great my friend

-- Jesus Is Alright with me

View Dave's profile

Dave

11137 posts in 1436 days


#11 posted 149 days ago

Randy I see the talent in your jigs and fixtures. Really.
So we need a fair sized project out of you.
This one is awesome.

-- Superdav "No matter where you go - there you are." http://chiselandforge.com

View DIYaholic's profile

DIYaholic

12860 posts in 1271 days


#12 posted 149 days ago

Matt,
Thanks.
If you don’t go for “perfect”, then (non) squaring the fence is easy!!! Lol.
I’m going to re-address the square-ish-ness of the fence, once my brain is less foggy!!!

Eddie,
I appreciate the kind words.

Dave,
Glad YOU can see the talent….
Projects are on the horizon….
I promise!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View Doe's profile

Doe

924 posts in 1426 days


#13 posted 149 days ago

Well done and looks really great too! Thanks for sharing the build. Can’t wait to see what you do with it.

-- Mother Nature talks, I try to listen

View helluvawreck's profile (online now)

helluvawreck

15389 posts in 1463 days


#14 posted 149 days ago

That will certainly be a wonderful addition to your shop and you presented it quite well.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View a1Jim's profile

a1Jim

111999 posts in 2173 days


#15 posted 149 days ago

Wow Randy
I thought you said ” I decided not to over complicate things ” If this is you basic sled wow just wow,very cool.

-- http://artisticwoodstudio.com Custom furniture

showing 1 through 15 of 22 comments

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