Cross Cut Sled

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Project by Tony1212 posted 12-07-2015 07:46 PM 1896 views 9 times favorited 3 comments Add to Favorites Watch

I combined a couple ideas I got from Stumpy Nubs and Popular Woodworking to come up with this.

I combines the zero clearance replaceable kerf on the base from Stumpy Nubs sled with the zero clearance fence of the Popular Woodworking sled.

Unlike Stumpy’s zero clearance base that was routed for a hardboard strip, I laminated two 1/8” hardboard pieces to a 1/2” MDF base with 3” strip that can be replaced. It slides in easily from either the front or back of the sled.

The MDF pieces on the fence can be removed, cut, then reattached to provide a backing for cuts.

With this setup, I can easily move from dado cuts to single blade cuts and still protect from tearout.

There is also an extendable stop block that I stole from Popular Woodworking’s plans. It uses angle aluminum that is pretty sturdy to the full extension. In the future, I will probably add Stumpy’s idea of a bottom support to hold up the piece being cut.

The angle aluminum and the T-track were all 3ft long, so that is how long the sled is. Using the 5 cut method, I was able to square the fence to within 0.02” over the ~1.5ft capacity of the sled. It could be better, but I figured at that point it wasn’t worth my time. I had other stuff to get done. I figure that if at some future time that I need it better than that, I can fiddle with it more then.

-- Tony, SW Chicago Suburbs

3 comments so far

View helluvawreck's profile


32087 posts in 3066 days

#1 posted 12-07-2015 08:21 PM

It’s a nice sled. What is the max that you can crosscut?

helluvawreck aka Charles

-- helluvawreck aka Charles,

View Northwest29's profile


1661 posts in 2689 days

#2 posted 12-07-2015 08:24 PM

I like the way you have incorporated features from different sources to come up with a cool sled. Thanks for sharing.

-- Ron, Eugene, OR, "Curiosity is a terrible thing to waste."

View Tony1212's profile


250 posts in 1934 days

#3 posted 12-07-2015 08:31 PM

Charles, I can only get about 1.5 feet. Maybe a bit more. It was only a two foot wide piece of MDF, then there is the adjustable fence, the movable faces, and the back fence taking up about 6 inches. But thanks to the box where the blade comes out, it is much safer than my old sled.

Ron – Thanks!

-- Tony, SW Chicago Suburbs

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