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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 78 days ago 2790 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

765 posts in 544 days


#1 posted 78 days ago

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 84 days


#2 posted 78 days ago

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

279 posts in 1703 days


#3 posted 78 days ago

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

497 posts in 2298 days


#4 posted 78 days ago

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

14878 posts in 1820 days


#5 posted 78 days ago

Nice job,,, I couldnt live without mine.

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

View English's profile

English

190 posts in 109 days


#6 posted 78 days ago

Great Idea!! Thanks for sharing.

-- John, Suffolk Virgina

View KelvinGrove's profile

KelvinGrove

765 posts in 544 days


#7 posted 78 days ago

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

38 posts in 122 days


#8 posted 77 days ago

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

-- Oldstarter

View KelvinGrove's profile

KelvinGrove

765 posts in 544 days


#9 posted 77 days ago

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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