|Project by athomas5009||posted 04-14-2016 02:12 PM||1986 views||21 times favorited||8 comments|
I have been wanting a new crosscut sled since I got my cabinet saw last summer. I still had my old contractors saw and the sled but it was a basic sled and was lacking in some areas. So after doing a little research and incorporating some of my own ideas this is what I came up with.
1.) The fancy Incra adjustable Miter slides. The hardened steel ones. Make sure you break all the edges with 220grit These come with sharp edges that will scratch your saw top if they are not broken.
2) A stop block that is readily at hand without having to reach for a bulky clamp. The tounge in the rear of the block slides in the track. This keeps it square and leaves 1/8 dust clearance at the bottom.
3) Some T-track on the sled carrige so hold downs could be used for tricky cuts. I drilled a 1/2 hole near the front fence so the bolts can be removed.
4) I wanted to attach the rear fence with 1/4 bolts, tnuts and oversized holes in fence. This eliminates the Swiss cheese on the bottom during alignment. Also it makes the fence easily adjustable when necessary. I made the fences 2 1/8 thick so they were strong enough to remove the material needed to incorporate the features.
5) I also wanted oversized zero clearance plates that could be swapped out. This way I could use a dado stack, or switch out worn plates. Their made of 2 glued up pieces of 1/8 hardboard. 6-32 inserts and screws were used to hold them in place. For the bottom plate I used some tape for shims to get it flush. I didn’t want to mess with set screw and drill more holes in a thin area.
6) I wanted this sled to be bigger. I picked 47.5×26 this way I could easily make cabinet parts. My last sled was only 23” deep and it was annoying.
7) Lastly I wanted a convient method of storage. Med/Lg sleds are difficult to store without taking up shop space. I put 2×1 1/2 holes in the base so it can be stored on rubber coated hooks from the ceiling.
After calibration I got it to within .001 with the 5 cut method, then confirmed it with another round. I’m pleased with the outcome expect this sled to see a lot of use. I tried to give some tips above for anyone that try’s to make something similar.
-- Sometimes you're flush and sometimes you're bust, and when you're up, it's never as good as it seems, and when you're down, you never think you'll be up again, but life goes on.