With the new saw I have needed to make a new crosscut sled. I have been struggling with cutting large plywood panels so I also decided to make a panel cutting sled based on Norm's design
I started by planing some white oak to fit in the miter slots.
The runners are set just below the table surface.
I attached the runner to a 3 foot run of plywood….
.... and ran the ply through the saw.
I attached a fence to the back of the sled square to the cut edge.
It took a slight adjustment but it now cuts perfectly square panels.
I have figured out some tricks to building the tradititional crosscut sled.
1. I attached one runner squarish to a 2 foot long panel.(I have not seen this direction before as most articles have you attach both at once).
2. Then I set the other runner on the saw with the panel down but overhanging the edge.
I clamp it and then screw up into the panel.
3.I attached the back fence. This is just for support and keeps the sled from falling apart once you cut through it. Then I cut through it.
4. I screwed on the front fence square to the saw kerf. (no photo) I then cut into the front fence. A test cut confirmed the sled cuts square. Last time I made one it took many tries.
5. I glued on a guard block.
shot from the bottom.
Not as pretty as the first one, but it works.
My old sled.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne