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
GaryK
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10263 posts in 2185 days
#1 posted 1947 days ago
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
Dorje
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1761 posts in 2194 days
#2 posted 1947 days ago
2 for 1 sleds I see… Nice work…
-- Dorje (pronounced "door-jay"), Seattle, WA
Scott Bryan
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27253 posts in 2019 days
#3 posted 1946 days ago
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
Thos. Angle
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4400 posts in 2159 days
#4 posted 1946 days ago
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
Grumpy
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#5 posted 1946 days ago
Great job Gizmo. Things can only progress from here.
-- Grumpy - "Always look on the bright side of life"- Monty Python
Bob #2
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#6 posted 1946 days ago
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
gizmodyne
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1762 posts in 2287 days
#7 posted 1946 days ago
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
gizmodyne
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#8 posted 1944 days ago
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
Yettiman
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160 posts in 1935 days
#9 posted 1934 days ago
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
gizmodyne
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1762 posts in 2287 days
#10 posted 1934 days ago
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
Yettiman
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160 posts in 1935 days
#11 posted 1934 days ago
Thanks Gizmodyne, much appreciate, Will try that next time.
-- Keep your tools sharp, your mind sharper and the coffee hot
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