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Adjustable Crosscut Sled, Box Joint Jig

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Project by Greg Wurst posted 1874 days ago 8472 views 45 times favorited 9 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.





9 comments so far

View a1Jim's profile

a1Jim

112008 posts in 2201 days


#1 posted 1874 days ago

very cool jig well done

-- http://artisticwoodstudio.com Custom furniture

View POPSHOP's profile

POPSHOP

125 posts in 1876 days


#2 posted 1874 days ago

awesome jig and the saw cab is too !

-- POPSHOP ,

View Brad_Nailor's profile

Brad_Nailor

2531 posts in 2582 days


#3 posted 1874 days ago

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 2545 days


#4 posted 1874 days ago

Very nice, I need one of these.

View Greg Wurst's profile

Greg Wurst

780 posts in 2457 days


#5 posted 1874 days ago

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 2369 days


#6 posted 1874 days ago

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 1948 days


#7 posted 1872 days ago

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

780 posts in 2457 days


#8 posted 1872 days ago

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

141 posts in 1317 days


#9 posted 1301 days ago

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

-- Paul, Plantagenet, Ontario

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