Tonight I thought I would get started on my cross cut sled. Bad idea. My garage is not climate controlled and it is 101 degrees outside. Needless to say I didn’t get a lot done.
The overall dimensions will be 36” wide and 24” deep. I am using 1/2 BB plywood for the base, 3/4 bb plywood for the front fence, and 4/4 hard maple for the rear fence and the runners.
Step 1 – Runners. My idea actually worked out well. I started with 4/4 maple. I ran it through the planer until the end fit super snug in the miter slot:
After many VERY light passes, I got the fit I wanted
Next up, cutting them down to size. I didn’t want the sled to ride over the table, so I wanted to cut the runners a tad shallow. With the maple in the slot, I marked it with a pencil. I then ripped a piece off and split the pencil line
That worked perfect! They are just a hair below the table.
Next up, cut the plywood to size. After that. I marked a line every 7.5”. 6 1/4” from the back, 2.5” from the front and drilled some holes. I am going to be using woodpeckers jig fixtures. The bolt is 1/4”, the nut is 3/8”. I drilled a 1/4” hole in the front to start the dado, and a 1/2” hole in the end. Why? I’ll get to that in a minute:
I then routed a 1/4” dado through the board using the 1/4 hole as a center. I then used the 1/2” hole to route a 1/2 wide dado on the bottom, but only 3/16” deep. Effectively I have made myself a T-track. I can sneak the bolt through the 1/2” hole and have the nut recessed, while the bolt protrudes from the table to allow me to lock down the miter guides and other fixtures I plan on making, like a tenoning jig.
I also got the fence glued up. The fence will be as long as my table, which is about 47”. I doubled up on the plywood and glued them together. Given the size of this thing, I may tripple up and use 3 4” high by 3/4 thick pieces. I want to see how rigid 1 1/2” feels first. I used the rest of that maple for the back fence. Again, I doubled it up and glued it, so it’s about a foot long and 1 1/2” thick. I threw some brads in there to index it, but nowhere near the middle so I don’t run the risk if nicking the blade on one
That’s as far as I got. It is WAY too hot out and I am starting to get dehydrated. If anyone cares, stay tuned for more tomorrow
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