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Crosscut Sled and spline jigs

I had some time to make a new sled while waiting for my first bandsaw to arrive. This my fifth sled in the last 30 years and my best yet. The base and fences are phenolic plywood. The single slot runner and support structures are aluminum. The single runner design allows me to use one slot for 90 degree cuts and the other for 45s. Rear fence alignment to less than 0.003 inches per ft was accomplished using the William Ng 5 Cuts to a Perfect Cross-Cut Sled

My intention is to learn how to resaw for grain pattern matching. Some boxes from lumber that somehow has lived on the rack for >10 years should be good for skills development. All will have with mitered and splined corners. I'll make boxes in sets to provide opportunity for repetition on same cut to develop my consistency. Then each set of different size and wood variety to provide repetition on set up. The sled and jigs will be instrumental.

I'll post pictures of the resulting boxes next…

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Comments

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1,833 Posts
Great job, we get alo of uses from our sleds. Love the spline jig, well done.
 

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Real nice sled and nice fixture BUT - Where's the saw dust ? where's any dust, it looks like a 'clean' room from CSI
 

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Thanks! I do try to keep a dust free shop. I'll post pics of my ever improving collection system.
 

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Nice.
 

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425 Posts
Congrats on your 1st DT3. Nice sled. I would encourage you to put some blade protection on the back side of the back fence just for safety sake.
 

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Thanks! I do try to keep a dust free shop. I'll post pics of my ever improving collection system.

I anxiously await the PICTURES of you dc system, unfortunately my system seems to be a broom.
 

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42 Posts
Nice project. Excellent choice of materials for the sled.
 

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Thank you for the kind comments.

Regarding dust collection, see http://lumberjocks.com/projects/111874 , Blast Gates and Manifolds. It shows the main dust collector. I have also a Fein shop vac that is helpful over the blade.

Regarding no blade guard on the sled. Yes, I plan adding that soon.
 

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544 Posts
Beautiful Sled!!! I would like to know the details on the aluminum rear fence and also the micro adjuster.
Who made them and where did you get them? Super slick !!
 

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The aluminum rear fence angle is from Rockler, purchased more than a year ago and I've not seen one since. I think I saw a similar one in silver at Peachtree Woodworking Supply Inc. but I do not see it in the online catalog.

The micro adjuster is from Rockler. I think it is a part of the Kreg router table but I found it separately.
 

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88 Posts
Very nice rigs you have put together, they should serve you well for years to come. I have put together several sleds over the years and can't imagine life in the shop with out one. Thanks for sharing.
 
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