newTim's Wholly Adequate Crosscut Sled

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Project by newTim posted 07-31-2011 06:17 AM 4632 views 22 times favorited 14 comments Add to Favorites Watch

This is the second sled I’ve built. The first sled, built for a unisaw, was very accurate, but also very heavy. It had a 3/4” plywood bottom and solid maple fences. It also had maple runners which seemed to expand and contract with the weather.

To make this sled a little lighter I used 1/2” carboard as a filler between two 1/8” panels. The frame is just 1/2” plywood and the fences are two pieces of 1/2” plywood. They are attached with 2” pocket hole screws from the bottom. The front sled was attached with one screw and then squared to the sawblade before securing it with the remaining screws. It is lightweight, but sturdy, and seems to be accurate. I was also able to figure out how to attach the metal Incra Miter Sliders.

The last picture shows my laminate/veneer press made out of pipe clamps.

-- tim hill

14 comments so far

View Jack Barnhill's profile

Jack Barnhill

366 posts in 3391 days

#1 posted 07-31-2011 06:32 AM

That’s a great looking sled and a very interesting concept. How much weight do you figure you cut out?

-- Best regards, Jack -- I may not be good, but I'm slow --

View mahadevwood's profile


415 posts in 3045 days

#2 posted 07-31-2011 06:45 AM

Wow it’s really nice concept.

View newTim's profile


608 posts in 3632 days

#3 posted 07-31-2011 07:24 AM

I figure it is about 60%-70% of a similar sheet of 3/4” ply, maybe a little more. I forgot to mention that I also glued 3/8” strips of maple to the bottom of the fences so the screws would have something solid to bite in to. Here’s a little detail on the rear blade guard.

-- tim hill

View CharlieM1958's profile


16275 posts in 4244 days

#4 posted 07-31-2011 03:22 PM

Looks much more than “wholly adequate” to me.

-- Charlie M. "Woodworking - patience = firewood"

View AkBob's profile


201 posts in 2572 days

#5 posted 07-31-2011 04:50 PM

Beautifully done!

View Don Johnson's profile

Don Johnson

686 posts in 2806 days

#6 posted 07-31-2011 05:19 PM

At first I thought that the handhold recess was at the operator’s end of the sledge and my blood ran cold – then I saw the rear blade guard and realised my mistake – phew!

Nice job.

-- Don, Somerset UK,

View Ken90712's profile


17563 posts in 3214 days

#7 posted 07-31-2011 06:09 PM

Nice looking sled and interesting concept of how to make it lighter. Well done.

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

View Per Isacsson's profile

Per Isacsson

66 posts in 2595 days

#8 posted 07-31-2011 06:53 PM

Nice idea too get rid of some weight this way! I like your vaneer press setup. I think I will simply copy it. Perfect for my limited space.

-- Per I

View WayneC's profile


13754 posts in 4123 days

#9 posted 07-31-2011 06:55 PM

If I ever get stuck, I know who I am going to go to for advise… : ^ ) (You or John)

I think you live all of about 20 minutes from me.

-- We must guard our enthusiasm as we would our life - James Krenov

View TopamaxSurvivor's profile


18288 posts in 3701 days

#10 posted 07-31-2011 09:14 PM

Nice job. I am finally breaking down and making a “wholy adequate” box joint jig.

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View terry603's profile


320 posts in 2939 days

#11 posted 07-31-2011 11:02 PM

a lot of detail , looks as good as it funtional

-- may not always be right,but,never in doubt.

View David Murray's profile

David Murray

187 posts in 3140 days

#12 posted 08-01-2011 01:49 AM

I built one very similar to yours and works very well.

-- Dave from "The Sawdust Shed"

View doncutlip's profile


2832 posts in 3581 days

#13 posted 10-09-2011 01:42 AM

How do you square the fence to the blade?

-- Don, Royersford, PA

View newTim's profile


608 posts in 3632 days

#14 posted 10-10-2011 08:21 AM

The middle picture on the left shows how I squared the fence. First I squared the table using the rip fence. Then I put one screw in from the bottom on the right side and squared the fence to the blade and clamped it in place to make a couple of test cuts. It was accurate so I put a few more screws in through the bottom.

-- tim hill

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