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Super precise crosscut sled with a 99% dust collection hood - just $2.50

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Project by ChuckM posted 06-10-2014 12:09 PM 2954 views 28 times favorited 9 comments Add to Favorites Watch

For my new SawStop saw, I built a crosscut sled, following more or less Matt’s approach (but not his sequence of construction): http://www.finewoodworking.com/item/39002/build-a-super-precise-tablesaw-crosscut-sled

Two modifications:

1) I milled two runners (maple stock) very slightly over-sized and then planed it down to perfect width to fit the slots (Tip: Cut the runners with the grain running vertically (viewed from the end grain) to avoid their side to side movement.)

2) A dust collection and safety hood was added. SawStop claims a 99% dust collection with the use of its dust shroud. This shop-made dust collection hood also seems to leave no visible dust on the sled at all when making cross cuts (see last pic).

The whole jig was built using scrap lumber, polycarbonate sheet, and supplies except the elbow bent which was $2.5 from Lowe’s.

-- The time I enjoy wasting is not time wasted





9 comments so far

View KelvinGrove's profile

KelvinGrove

836 posts in 570 days


#1 posted 06-10-2014 01:22 PM

Chuck, It looks like your dust hood is flat on the bottom. Is that the case? I assume it means that there is a gap created by the near end of the hood sitting on top of the workpiece and the far end sitting on the bottom of the sled. This would leave a gap for air to enter and flow into the collection hose. If this is not the case, how do you handle both the gap and air induction?

By the way, adding this to my list of “must have shop tools”.

-- Tim P. Calhoun GA. Don't cry because it's over, smile....because for 7 glorious miles, everyone thought you were the real bus driver!

View WoodlandSprite's profile

WoodlandSprite

17 posts in 110 days


#2 posted 06-10-2014 02:14 PM

very nice!

-- woodlandsprite * Setting out to change the world is for most of us doing the best we can to improve our little corner of it.*

View Rob's profile

Rob

291 posts in 1729 days


#3 posted 06-10-2014 02:53 PM

Looks great! The dust shroud is a really good idea.

I might steal this but will probably use polycarbonate instead of acrylic for the extra safety and ruggedness.

View ChuckM's profile

ChuckM

501 posts in 2324 days


#4 posted 06-10-2014 03:07 PM

Hi Kelvin,

Your observation is correct and the hood is flat on the bottom. The SawStop dust collection system extracts dust both below the table and from above through the dust shroud. To really replicate the dust shroud, one can install “fins” on the sides of the hood similar to the design used by SawStop. See the pic. below:

However, in use, I didn’t find visible dust on the sled with the current flat bottom design, probably because the suction force both up and below the sled was strong enough.

Thanks for looking.

Chuck

PS to Rob—I corrected the material name, thanks.

-- The time I enjoy wasting is not time wasted

View Ken90712's profile

Ken90712

14947 posts in 1847 days


#5 posted 06-10-2014 04:52 PM

Nice job,,, I couldnt live without mine.

-- Ken, "Everyday above ground is a good day!"

View English's profile

English

213 posts in 135 days


#6 posted 06-11-2014 12:52 AM

Great Idea!! Thanks for sharing.

-- John, Suffolk Virgina

View KelvinGrove's profile

KelvinGrove

836 posts in 570 days


#7 posted 06-11-2014 02:34 AM

Well everybody,

-- Tim P. Calhoun GA. Don't cry because it's over, smile....because for 7 glorious miles, everyone thought you were the real bus driver!

View oldstarter's profile

oldstarter

40 posts in 149 days


#8 posted 06-11-2014 09:11 AM

Oh! No! I’m going to have to build another one now. Thanks Chuck.

-- Oldstarter (Dave Ashby)

View KelvinGrove's profile

KelvinGrove

836 posts in 570 days


#9 posted 06-11-2014 02:51 PM

Sorry about that last post guys…I got it on the wrong thread!

-- Tim P. Calhoun GA. Don't cry because it's over, smile....because for 7 glorious miles, everyone thought you were the real bus driver!

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