Cross Cut Sled #3: The 5 Cut Square Dance

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Blog entry by Jon3 posted 12-09-2007 02:31 AM 6822 reads 18 times favorited 10 comments Add to Favorites Watch
« Part 2: Fences! Part 3 of Cross Cut Sled series Part 4: Dressin' it all up. »

Now here is something else I didn’t do last time. Properly squaring up the sled.

I start by lining up my nice new fence, and dropping ONE screw only on the far side.

Then I slice a kerf just high enough to pop through the ply, and line up the fence roughly with the square. (This part is NOT how it gets squared… read on!)

Looks square, doesn’t it?


I made a small T adjustment block, and grab about 1/16 inch worth of sliced up index card and paper, and jam it in between the sled fence, and the block.

I flip the sled over, and screw my adjustment block in place.

Then I flip it back, and clamp that monster together.

Note: When you’re trying for something this precise, you have to keep the saw, and the sled clean. You are trying for hundredths of an inch accuracy, so dust like this can throw the whole thing off.

I vacuumed in between each test run.

I begin the 5 cut squaring process. You can read about it here.

After 7 runs, I finally got it accurate. And far more accurate than I ever expected:

Zero slop!

10 comments so far

View Lee A. Jesberger's profile

Lee A. Jesberger

6819 posts in 3403 days

#1 posted 12-09-2007 03:12 AM

Ah, nothing like accuracy.


-- by Lee A. Jesberger

View Thos. Angle's profile

Thos. Angle

4445 posts in 3386 days

#2 posted 12-09-2007 04:59 AM

good way to get it right.

-- Thos. Angle, Jordan Valley, Oregon

View mski's profile


418 posts in 3404 days

#3 posted 01-28-2008 11:43 PM

I know an old post but I been banging my head against the cast iron for a week trying to get my sleds square!
Just want to thank you for you tutorial, works GREAT!!!
Suprising what a regular piece of paper shim has on fence adjustment!
Thanks again


View Jon3's profile


494 posts in 3529 days

#4 posted 01-28-2008 11:49 PM

Glad it worked out for you!

View rikkor's profile


11295 posts in 3298 days

#5 posted 01-29-2008 12:29 AM

Great explanation. Thanks.

View dlgWoodWork's profile


159 posts in 3178 days

#6 posted 02-21-2008 11:50 PM

Great sled tutorial.
Something is wrong with your five cut method link.

-- Check out my projects and videos

View davidtheboxmaker's profile


373 posts in 3229 days

#7 posted 02-21-2008 11:56 PM

A friend’s got a new saw arriving tomorrow, so this is a really useful posting.
Like DGunn, I’m having problems linking to the 5 cut method – hope you get it fixed.

View dlgWoodWork's profile


159 posts in 3178 days

#8 posted 02-23-2008 05:50 AM

The five cut method link is working now. Thanks again for the excellent tutorial. I needed to make a more accurate sled, and this did just the trick.

-- Check out my projects and videos

View BarryW's profile


1015 posts in 3330 days

#9 posted 04-08-2008 02:42 AM

thanks for your postings on a crosscut sled…got some ideas.

-- /\/\/\ BarryW /\/\/\ Stay so busy you don't have time to die.

View Sac's profile


268 posts in 3057 days

#10 posted 06-29-2008 10:35 PM

Very nice 5 cut squaring process…

-- Jerry

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