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Cross Cut Sled

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Project by MickeyD posted 09-08-2009 12:45 AM 4497 views 30 times favorited 19 comments Add to Favorites Watch

I have finally finished our cross cut sled. After a few false starts (Chinese plywood) and miss turns it is finished and cuts square. I thank Kelly Mehler for inspiration. Whenever I would feel frustrated or unsure I would watch his video and feel calm and confident again. Jed (Kindlingmaker) was ever patient and supportive….I think he just wanted the sled finished and usable. ; ) We bought a saw blade just for cutting plastic to make the safety cover and it worked well. The front fence was not quite square after sitting around so long, but a couple of passes through the drum sander fixed that. The base is 1/2” Baltic birch plywood and the fences are 5-4 red oak. The safety block is several pieces of red oak glued together. The sled is 20” x 34” and has a fence height of 4 1/2”. The plexiglass safety cover reduces the amount of sawdust being thrown into the air besides helping to hold down the wood and keeping my fingers away from the blade. The guard is made of 1/4” plexiglass and I dado cut the groves in the fences to hold it in place. Johnson’s paste floor wax was applied to the bottom for smooth sliding action. I am very happy with the project and I am looking forward to years of use. : )

-- -Willing to try





19 comments so far

View Innovator's profile

Innovator

3584 posts in 2162 days


#1 posted 09-08-2009 12:48 AM

Congrats, Nice job

I really like the lexan saw guard.

-- Whether You Think You Can or You Think You Can't, YOU ARE RIGHT!!!

View Scott Bryan's profile

Scott Bryan

27251 posts in 2570 days


#2 posted 09-08-2009 12:56 AM

This is a nice sled, Mickey. I like the addition of the blade guard as well. I put one on mine because I have a bad habit of reaching inside the sled for the offcuts before the blade stops spinning. But I only put a shield in place and, you are right, it does throw off sawdust. I like the enclosed guard that you built not only for safety’s sake but also for controlling dust.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View cabinetmaster's profile

cabinetmaster

10874 posts in 2307 days


#3 posted 09-08-2009 01:03 AM

Nice job. Looks like the same size one I had at my cabinet shop. Cut many a cabinet part with it. Wish I had never parted with it or the saw.

-- Jerry--A man can never have enough tools or clamps

View BarryW's profile

BarryW

1015 posts in 2655 days


#4 posted 09-08-2009 01:09 AM

that’s an excellent sled…and from the sounds of it is very smooth…and I like the guard…excellent.

-- /\/\/\ BarryW /\/\/\ Stay so busy you don't have time to die.

View GrainTrain79's profile

GrainTrain79

20 posts in 1932 days


#5 posted 09-08-2009 01:39 AM

Nice!

I recently built a sled and I love it. It makes cutting a joy. I find that it really helps to control the dust too.

-- West Seattle, WA

View GrainTrain79's profile

GrainTrain79

20 posts in 1932 days


#6 posted 09-08-2009 01:40 AM

what do you use for runners beneath? a piece of hardwood? or a piece of aluminum or brass? is there any play? One runner or two?

-- West Seattle, WA

View Matt Vredenburg's profile

Matt Vredenburg

129 posts in 2163 days


#7 posted 09-08-2009 03:39 AM

Congratulations on completing your cross cut sled. I know how projects can drag on and being able to say you completed something is a great feeling. I have build three cross cut sleds in my lifetime and each one gets better and better. Great job – i love the Plexiglas idea for safety.

-- Matt, Arizona

View MickeyD's profile

MickeyD

130 posts in 2275 days


#8 posted 09-08-2009 03:49 AM

GrainTrain79 I used 2 steel miter bars from Peachtree. They have spring plungers that can be adjusted to stop side to side play.

~Mickey

-- -Willing to try

View upperwoodsman's profile

upperwoodsman

40 posts in 2094 days


#9 posted 09-08-2009 05:34 AM

Hey I like the hole idea very useful Congrats
Nice Plexiglas idea

-- Scott JoBurg MI The More you know the less mistakes...........

View Big_Bob's profile

Big_Bob

167 posts in 2458 days


#10 posted 09-08-2009 04:33 PM

Nice. I like the plexiglass safety cover. I may need to scrap mine out and make one like yours.

-- Bob Clark, Tool Collector and Sawdust Maker

View woodworm's profile

woodworm

14134 posts in 2339 days


#11 posted 09-08-2009 08:27 PM

Nicely built sled.

-- masrol, kuala lumpur, MY.

View HarleySoftailDeuce's profile

HarleySoftailDeuce

273 posts in 2168 days


#12 posted 09-09-2009 06:52 PM

Very nice sled! Every time I come on this site, I add things to my to do list, and this is one of those items I really could use.

-- Paul, Bristol,Rhode Island

View panther's profile

panther

59 posts in 1992 days


#13 posted 09-12-2009 03:54 AM

outstanding sled,very glad to see plexyglass shield cover the blade, the first time your fingers bump it instead of the spinning blade they will thank you

-- you must live for something or die for nothing (rambo)

View Woodlander's profile

Woodlander

9 posts in 2076 days


#14 posted 09-27-2009 04:15 AM

Wow – this is great!

I saw the one you based it on in a fine woodworking video – and yours is superb!

Great job!

-Woodlander

-- "Government "help" to business is just as disastrous as government persecution... the only way a government can be of service to national prosperity is by keeping its hands off. " - Ayn Rand

View reggiek's profile

reggiek

2240 posts in 2019 days


#15 posted 09-27-2009 04:43 AM

Cool Sled….one of the most useful jigs IMHO….that one is a keeper for sure…

-- Woodworking.....My small slice of heaven!

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