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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 8589 views 46 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

112093 posts in 2232 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 1906 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

2531 posts in 2613 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 2575 days


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

Very nice, I need one of these.

View Greg Wurst's profile

Greg Wurst

781 posts in 2488 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 2400 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 1979 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

781 posts in 2488 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

141 posts in 1348 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

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