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Ultimate Crosscut Sled

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Project by bj383ss posted 08-06-2017 01:51 PM 3429 views 15 times favorited 15 comments Add to Favorites Watch
Ultimate Crosscut Sled
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I finally built the crosscut sled I have been wanting for years. After 9 years my old sled was out of alignment, wore, and just too small. So I built this one loosely following the Ultimate Crosscut Sled. It’s cabinet grade ply and Mahogany. It measures 27” x32”. It has a flip stop that I really like and the center has a removable insert to accommodate different blade widths. It has also for T-slots for hold downs or miter fences. I finished it with 2 coats of Poly. So far it works great. Only downside is it is heavy. However I acquired another tablesaw. So I plan to set that one up with this crosscut sled on it so I don’t have to remove it.

-- https://www.flickr.com/photos/27291602@N03/





15 comments so far

View tyvekboy's profile

tyvekboy

1774 posts in 3063 days


#1 posted 08-06-2017 02:16 PM

Beautiful crosscut sled. Love the mahogany. If you could add a few more photos of how the center insert works that would be great.

For the weight, you might be able to route out areas on the bottom of the sled about 1/4 to 3/8 inch deep to get some of the less required wood out. Should work without affecting the function of the sled.

Also the back board really doesn’t have to be that long. 18 inches (9 inches either side of the kerf should be sufficient to hold the board together. That should also help reduce the weight.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View LittleBlackDuck's profile

LittleBlackDuck

1830 posts in 870 days


#2 posted 08-06-2017 02:28 PM

Neat looking job. Looks really solid so I can appreciate your concern about the weight. However, if you are fortunate enough to set up a dedicated tablesaw, who cares!

-- If your first cut is too short... Take the second cut from the longer end... LBD

View splintergroup's profile

splintergroup

2140 posts in 1272 days


#3 posted 08-06-2017 02:32 PM

A work of art!
What did you use for runners (they look like wood strips) and did you put anything on the base to reduce sliding friction (my main issue when pushing a large sled)?

The replaceable insert is probably the most under appreciated feature, you should get a lifetime of use from this.

View Mainiac Matt 's profile

Mainiac Matt

8153 posts in 2378 days


#4 posted 08-06-2017 03:40 PM

Nicely done!

-- It’s the knowledge in your head, skill in your hands and motivation to create in you heart that makes you a woodworker. - Mainiac Matt

View bj383ss's profile

bj383ss

193 posts in 2411 days


#5 posted 08-06-2017 04:15 PM


Beautiful crosscut sled. Love the mahogany. If you could add a few more photos of how the center insert works that would be great.

For the weight, you might be able to route out areas on the bottom of the sled about 1/4 to 3/8 inch deep to get some of the less required wood out. Should work without affecting the function of the sled.

Also the back board really doesn t have to be that long. 18 inches (9 inches either side of the kerf should be sufficient to hold the board together. That should also help reduce the weight.

- tyvekboy

Thank You Tyvek. Here some pictures from Garage Journal thread of the build. Maybe I should do a blog on the sled?

Runners ready to go with some double sided tape. Washers in the miter slots to elevate the runners above the tablesaw so they will contact the sled.

Time for some screws. First try I didn’t clamp the runners in place just ran the screws in. The one on the right moved just enough that it made the sled too hard to move back and forth. So I took it loose and the second time I clamped it in place before screwing.

This beautiful piece of wood will become the fences.

8/4 Mahogany(not African)

This baby is dense and heavy.

Jointed one edge. Which I didn’t photograph. It was a work out on my 6” jointer. About to rip it in half with the jointed side against the fence.

Set the Planer up for some action.

After both sides where planed. I cut it down to 1 5/8” on the bandsaw to speed up the planning process to get it to 1 1/2” thick.

Both pieces planned and cut to size. Mockup. They are 4 3/8” high.

Next up was a dado stack in the table saw to make the cutout for the insert down the middle of the sled. This is the test piece.

Came out pretty good. Had to sand it just a little.

Flipped over installing the t-nuts that the hold down screws for the insert will go in. They are 8-32.

A shallow recess cut for the t-nuts with a forstner bit.

Inserts cut and drilled. All the holes lined up on the first try!

I cut 5 inserts while I had it setup.

Back fence installed. I still need to do some more sanding on it and run a 1/4” roundover bit on it.

Next thing to do is make the first cut.
Cut the 2 dadoes in the front fence for the T-Track and the tape measure and then get it mounted and square to the blade.

Extremely happy with how it has turned out so far. It is big and heavy but it will cut panels 25” wide.

Last but not least. My completed Red “X’s” for the month of March. With a total shop time of 98 hours. I am very happy with that. It has helped me with motivation tremendously.

Almost forgot the wife’s “Burger of the Day”

Bret

-- https://www.flickr.com/photos/27291602@N03/

View bj383ss's profile

bj383ss

193 posts in 2411 days


#6 posted 08-06-2017 04:16 PM

LBD – Thank You.

Splinter – the runners are hardwood. One is oak and one Pecan. I already had them made they both came from 2 old sleds that this new one replaced.

Matt – Thank You.

Bret

-- https://www.flickr.com/photos/27291602@N03/

View tyvekboy's profile

tyvekboy

1774 posts in 3063 days


#7 posted 08-06-2017 04:42 PM

Great photos of the build. Now it all makes sense. Thanks for adding them.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Northwest29's profile

Northwest29

1642 posts in 2540 days


#8 posted 08-06-2017 05:11 PM

Look to pretty to use, but definitely a practical addition to your shop. It ‘appears’ that you have to remove a fence to replace insert, or is there enough wiggle room under the fences?

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

View helluvawreck's profile

helluvawreck

31654 posts in 2916 days


#9 posted 08-06-2017 05:27 PM

This is a beautiful crosscut sled and a fine addition to your shop.

helluvawreck aka Charles
http://woodworkingexpo.wordpress.com

-- helluvawreck aka Charles, http://woodworkingexpo.wordpress.com

View woodbutcherbynight's profile

woodbutcherbynight

5215 posts in 2459 days


#10 posted 08-06-2017 09:17 PM

Nice work! That looks like a piece of furniture.

-- Live to tell the stories, they sound better that way.

View BurlyBob's profile

BurlyBob

5618 posts in 2315 days


#11 posted 08-06-2017 09:34 PM

That’s an awesome looking sled. Definitely to nice looking to use.

View crowie's profile

crowie

2503 posts in 2000 days


#12 posted 08-06-2017 10:32 PM

You don’t do things by half Bret….
They are always TOP SHELF in both quality and presentation…well done sir.

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View Grumpy's profile

Grumpy

24030 posts in 3901 days


#13 posted 08-08-2017 11:08 PM

Bj , nice job and congratulations on your ‘Daily Top 3’ award. Almost looks too good to use.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View pottz's profile

pottz

2697 posts in 1034 days


#14 posted 08-10-2017 07:31 PM

spectacular, without a doubt the nicest sled ive ever seen,and there are plenty posted here.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View bj383ss's profile

bj383ss

193 posts in 2411 days


#15 posted 08-10-2017 08:18 PM

Thank You guys for all the great comments.

Bret

-- https://www.flickr.com/photos/27291602@N03/

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