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Adjustable Crosscut Sled, Box Joint Jig

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Project by Greg Wurst posted 07-03-2009 02:51 AM 9131 views 47 times favorited 13 comments Add to Favorites Watch

This a crosscut sled design I got out of ShopNotes issue 99. It is adjustable in width for use with dado blades. There is an extension you can add for crosscutting longer pieces. The aluminum fence has a tape measure and stop for making accurate repeat cuts. I also added the box joint attachment. You can make multiple faceplates for different joint sizes. I made a 1/4”, 1/2”. and 3/4” to start. I wrote the exact combination of cutters and shims used for each size on the faceplate. The 3/4”” was used primarily to create the dentil piece you see in the last picture. It has a micro adjuster that allows you to easily fine-tune the width between the slots. I use this all the time now. The adjustable base means you only have one slot to align the fence, which is the only real drawback I see. The bar guide in the slot uses a spring-loaded ball bearing to keep it firm in the slot. If you push it too hard to the right you can knock your cut out of square. I just keep the pressure on the left side of the sled and it works great.

Oh yes, the Sketchup file:

http://cid-258899c12334cc4d.skydrive.live.com/browse.aspx/Crosscut%20Sled

-- You're a unique and special person, just like everyone else.





13 comments so far

View a1Jim's profile

a1Jim

112942 posts in 2331 days


#1 posted 07-03-2009 03:08 AM

very cool jig well done

-- http://artisticwoodstudio.com Custom furniture

View POPSHOP's profile

POPSHOP

125 posts in 2006 days


#2 posted 07-03-2009 03:15 AM

awesome jig and the saw cab is too !

-- POPSHOP ,

View Brad_Nailor's profile

Brad_Nailor

2532 posts in 2712 days


#3 posted 07-03-2009 03:29 AM

Thats a great sled! I like the Kreg flip stop system built in..nice..

Wheres the Sketch up Drawing? ;)

-- http://www.facebook.com/pages/DSO-Designs/297237806954248

View Christopher's profile

Christopher

573 posts in 2674 days


#4 posted 07-03-2009 03:31 AM

Very nice, I need one of these.

View Greg Wurst's profile

Greg Wurst

783 posts in 2587 days


#5 posted 07-03-2009 04:17 AM

Wheres the Sketch up Drawing? ;)

You mean this one?

http://cid-258899c12334cc4d.skydrive.live.com/browse.aspx/Crosscut%20Sled

Depending on your saw you may have to flip the way the sled is constructed.

-- You're a unique and special person, just like everyone else.

View tenontim's profile

tenontim

2131 posts in 2499 days


#6 posted 07-03-2009 02:57 PM

Nice design, with many useful possibilities. And, yeah, it should be on the other side of the blade. I don’t know how you right handed guys do anything. Thanks for the post.

View woodman71's profile

woodman71

162 posts in 2078 days


#7 posted 07-05-2009 02:26 AM

Great sled I really like the kreg system I have one question why is there a adjustable guide our like stop block on the back side of the back fence wondering what purpose it served.

View Greg Wurst's profile

Greg Wurst

783 posts in 2587 days


#8 posted 07-05-2009 03:21 AM

The adjustable block is part of the adjustable base that expands for dado cuts. It allows for a zero clearance cut at any blade width.

-- You're a unique and special person, just like everyone else.

View tyka's profile

tyka

142 posts in 1447 days


#9 posted 01-27-2011 05:22 AM

Smart design and great features. Tks for sharing. Can’t open the file though.

-- Paul, Plantagenet, Ontario

View Dambo29's profile

Dambo29

13 posts in 768 days


#10 posted 11-22-2014 03:16 AM

Hi Greg,
A while back I built a crosscut sled like yours (from Shopnotes #99). I too found it convenient but I have a question. Maybe it’s stupid and I just didn’t do it right, but when you use a dado set and you’re cutting through the material, doesn’t your rear fence get cut also effectively now no longer being a zero clearance fence for your regular blade?

The bottom part or base of the sled separates to make room for the blade thickness but the rear fence doesn’t. Right?

View Greg Wurst's profile

Greg Wurst

783 posts in 2587 days


#11 posted 11-22-2014 03:23 AM

You are correct. It will take a chunk out of the back of the sled if you use a dado blade. Doesn’t really affect much other than a potential for some exit tearout. As long as you adjust the width it can still function as a zero clearance sled for the majority of the cut.


Hi Greg,
A while back I built a crosscut sled like yours (from Shopnotes #99). I too found it convenient but I have a question. Maybe it s stupid and I just didn t do it right, but when you use a dado set and you re cutting through the material, doesn t your rear fence get cut also effectively now no longer being a zero clearance fence for your regular blade?

The bottom part or base of the sled separates to make room for the blade thickness but the rear fence doesn t. Right?

- Dambo29


-- You're a unique and special person, just like everyone else.

View Dambo29's profile

Dambo29

13 posts in 768 days


#12 posted 11-22-2014 03:49 AM



... for the majority of the cut.

Exactly. I’m trying to figure out a way to make it work for the entire cut. I think maybe adding a sliding front face.. maybe‚Ķ I’ll have to think about it more later. But Thanks!

View adamwidmer's profile

adamwidmer

1 post in 26 days


#13 posted 12-02-2014 01:00 AM

Maybe some type of replaceable piece in the back like on This One

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