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Crosscut Sled

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Project by sras posted 1309 days ago 16277 views 170 times favorited 51 comments Add to Favorites Watch

This crosscut sled was my second accessory I built for my table saw. I built this last summer from formica covered MDF and oak trim. I spent several hours searching the web for ideas that I wanted to include in my version. For some reason I never stumbled across Lumberjocks at that time. I saw a sled design on ShopNotes that is a starting point, but I made several improvements/changes. I have seen features here that I might add in the future. Let’s see if I can cover the details.

First is the size – it is 27” deep and 45” wide. This is as big as I felt I could handle. In the past year, there have been two times where friends have stopped by to use this sled because of its size.

I spent a lot of time getting the fence perfectly square. It took several clamped setups and test cuts before I was happy. Test cuts were done by squareing a wide board then flipping the board over and cutting a small piece off the end. The cutoff would show me twice the error of the fence. I would then cut four pieces and stack them to get a better estimate of the error.

The sled has two adjustable panels on each side of the blade. This way I can set the floor of the sled next to the blade even when I use a dado or tilted saw blade setup.

Edit
Cal asked for more information about the adjustable panels and runners. It seemed best to add that here rather than down in the comments. Each panel consists of the floor panel and a piece on each end. Each end is held in place with a bolt. That is a total of four bolts. You can see them in the first picture. There are total of 5 black knobs visible the lower right one is for an extension (described below). The remaining 4 knobs secure the adjustable panels. The first picture shows an end board fairly well – it is to the right of the blade guard (described in the next paragraph). The second picture shows another end piece well – on the back side and for the other adjustable panel. Hope that is clear ;)
The runners are hard maple. I used two of them. They were cut slightly (0.004”) large and fitted by sanding down.

End Edit

The box on the front of the sled completely covers the saw blade. This only works when used with my outfeed table . The stopped slots on the outfeed table stop the travel of the sled before it can pass through the blade cover (and then my hand). This is by far my favorite feature and one I highly recommend.

There are two adjustable miter fences – one right hand and one left hand. They rotate around a pivot point that is centered on the arc routed with a t-slot bit. Getting the pivot point and the arc concentric took some thinking but I figured it out!

There is an extension for cutting large panels. It locks into place with a single bolt.

Finally, there is a t-slot rail that runs the full length of the sled and the extension to let me lock down a stop block (which I have not yet built).

I find myself using this sled all the time.

-- Steve - Impatience is Expensive





51 comments so far

View jim C's profile

jim C

1449 posts in 1604 days


#1 posted 1309 days ago

Beautiful and very functional.
Thanks

-- When I was a boy, I was told "anyone can be President", now I'm beginning to believe it!

View Daiku's profile

Daiku

190 posts in 1413 days


#2 posted 1309 days ago

Steve

Like you, I’ve been looking for the “right” sled to justify the time and effort in making one. I think you have come up with just the design. This is ingenious from the way you can adjust for dadoes to the miter gauge. How do the panels adjust for the dado blades and what type of runners did you use?

Thanks for posting,

-- Cal Noguchi

View Tomoose's profile

Tomoose

278 posts in 1879 days


#3 posted 1309 days ago

Wow – that is a monster – love the design. Thanks for the post.

-- cut it twice and it's still too short...

View Ken90712's profile

Ken90712

14544 posts in 1694 days


#4 posted 1309 days ago

Man what a great looking sled. One of the best on here, well done.

-- Ken, "Everyday above ground is a good day!"

View mafe's profile

mafe

9243 posts in 1595 days


#5 posted 1309 days ago

Wauuuuu, thats one h… of a sled!
I would love to cruise up and down of wood alle on that thing.
Good thinking, and so beautifully made – love it!
Best thoughts,
MaFe

-- Mad F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View SplashMaster's profile

SplashMaster

153 posts in 1367 days


#6 posted 1309 days ago

great job very nice

View Kent Shepherd's profile

Kent Shepherd

2694 posts in 1792 days


#7 posted 1309 days ago

Excellent

Thank you for sharing

-- She thought I hung the moon--now she just thinks I did it wrong

View Diggerjacks's profile

Diggerjacks

1632 posts in 1644 days


#8 posted 1309 days ago

Waouh This is a beautiful piece

I love the design

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View zlatanv's profile

zlatanv

689 posts in 1740 days


#9 posted 1309 days ago

Wow, that looks awesome. Nice work on all your jogs.

-- Z, Rockwall, TX

View Routerisstillmyname's profile

Routerisstillmyname

653 posts in 2015 days


#10 posted 1309 days ago

Oh my, that’s not a Crosscut Sled, that’s lamborghini murcielago of sleds.

-- Router รจ ancora il mio nome.

View ScottnKY's profile

ScottnKY

109 posts in 1570 days


#11 posted 1309 days ago

You are not being honest. These are not Sleds and Jigs….That stuff is fine furniture !!!!

Awesome ….......I couldn’t use that. I would be afraid I would scratch it .

View McLeanVA's profile

McLeanVA

454 posts in 1940 days


#12 posted 1309 days ago

Good Lord that’s awesome!

I’m too hasty to get that detailed. Dovetails well with the reason why I still have to shim every board I cut on my homemade sled.

Nice work.

-- Measure, cut, curse, repeat.

View Chip's profile

Chip

1904 posts in 2598 days


#13 posted 1309 days ago

Spectacular… Wow… What everyone else has said. I have a monster of a sled that I thought was great and this puts it to shame. Beautiful work Steve. Love it!

-- Better to say nothing and be thought the fool... then to speak and erase all doubt!

View BritBoxmaker's profile

BritBoxmaker

4282 posts in 1542 days


#14 posted 1309 days ago

What a beauty. Comprehensive too. Well done sir.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View RexMcKinnon's profile

RexMcKinnon

2593 posts in 1701 days


#15 posted 1309 days ago

Cool, love the arm for the angled cuts.

-- If all you have is a hammer, everything looks like a nail!

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