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Shop Organization #7: Crosscut Sled version 2.0 and Panel Sled

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Blog entry by gizmodyne posted 02-19-2008 06:56 AM 14821 reads 18 times favorited 11 comments Add to Favorites Watch
« Part 6: Flip Top Planer Cart Part 4: Success! Part 7 of Shop Organization series Part 8: Workbench Cabinet (Part 1) »

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

Panel Sled

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.

Finished sled

Crosscut sled
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



11 comments so far

View GaryK's profile

GaryK

10262 posts in 2654 days


#1 posted 02-19-2008 08:00 AM

Pretty cool Giz. I will take a picture of mine to show you what I did differently.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Dorje's profile

Dorje

1763 posts in 2663 days


#2 posted 02-19-2008 08:28 AM

2 for 1 sleds I see… Nice work…

-- Dorje (pronounced "door-jay"), Seattle, WA

View Scott Bryan's profile

Scott Bryan

27251 posts in 2488 days


#3 posted 02-19-2008 01:15 PM

Getting new tools is fun but one of the benefits that we get from them is the shop time needed to make new jigs. One of the appealing things about projects like this is that we can get them together rather quickly rather than spending an inordinate time in the construction process.

Now you are ready to make some dust with your new saw.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View Thos. Angle's profile

Thos. Angle

4435 posts in 2628 days


#4 posted 02-19-2008 04:53 PM

Looks good to me, John. How pretty does it have to be to cut square? Does all your crew speak Espanol?

-- Thos. Angle, Jordan Valley, Oregon

View Grumpy's profile

Grumpy

19479 posts in 2517 days


#5 posted 02-20-2008 12:43 AM

Great job Gizmo. Things can only progress from here.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Bob #2's profile

Bob #2

3808 posts in 2688 days


#6 posted 02-20-2008 02:05 AM

Giz, one thing I do differently than you is to leave about 3-4 inches of runner hanging out the back of the sled.
It makes it a bit easier to align it to the grooves.

p.s. I munched the alignment really bad on the most recent 45° sled and had to do some ugly adjustments to it today but it works.

Bob

-- A mind, like a home, is furnished by its owner

View gizmodyne's profile

gizmodyne

1763 posts in 2756 days


#7 posted 02-20-2008 02:34 AM

Bob.

That is a good idea. I did that on the panel sled. I will see how I like it.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View gizmodyne's profile

gizmodyne

1763 posts in 2756 days


#8 posted 02-22-2008 06:46 AM

T.A.

Good point.

As for the Spanish. Yes. But the crew is me.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View Yettiman's profile

Yettiman

161 posts in 2404 days


#9 posted 03-02-2008 12:13 PM

Hi,

How do you fine tune it.

I have made a couple in the past, and although I was as accurate as I could be, they are not perfect, nearly so, but not, so I was wondering how to fine tune.

-- Keep your tools sharp, your mind sharper and the coffee hot

View gizmodyne's profile

gizmodyne

1763 posts in 2756 days


#10 posted 03-02-2008 03:37 PM

Yetiman:

When you first put the fence on, only use two or three screws and no glue. Drill a couple extra pilot holes though. Then take a sample cut and check for square. Move the fence as needed and put screws in the new holes.

Nikki, has an alternate method for making a sled that looks promising too. Good luck.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne

View Yettiman's profile

Yettiman

161 posts in 2404 days


#11 posted 03-02-2008 11:24 PM

Thanks Gizmodyne, much appreciate, Will try that next time.

-- Keep your tools sharp, your mind sharper and the coffee hot

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