|Project by jayman7||posted 07-12-2009 10:07 PM||3096 views||5 times favorited||7 comments|
I finally got around to building a crosscut sled for my table saw this weekend. It’s based on a Fine Woodworking article. I used quarter sawn (or close to it) red oak for the runners to minimize wood movement and attached them with 3/4” #6 wood screws. Base is approximately 24” x 20” 3/4” MDF. The rear fence is a beefy 2” thick, and 4” tall piece of poplar that was glued together (scrap piece I had laying around). It’s attached using three 5/16” diameter lag bolts fitted into T-nuts on the top. I chamfered the inside part keep a work piece seated properly with saw dust. The front fence was less important so i used a scrap piece of 2×4 attached with four screws. Waxed the bottom and runners and slides real well. The bolts made it easy to adjust it perfectly square to the blade. I might add a little block of wood on the rear part where the blade pops out so i don’t accidentally put my thumb there, but my fence is so tall and my thumb so short that it doesn’t reach there anyway.
Few things I learned:
It’s impossible for it to slide perfectly smooth after attaching the runners with screws even though they were milled perfectly. The screws makes the runners dift just enough to make it catch in the miter slot. I used to card scraper to remove the material that was catching. It leaves a dark streak that lets you know it’s catching in that particular spot. If I do it again, I might try using glue to attach the runners before using screws. Has anyone tried this method before?
And be sure to test your T-nuts before hammering them in! I used a badly threaded T-nut and stupidly forced the bolt in. Made it very difficult when I decided to replace it later.