newTim's Wholly Adequate Crosscut Sled

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Project by newTim posted 1096 days ago 3397 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 1970 days

#1 posted 1096 days ago

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


400 posts in 1623 days

#2 posted 1096 days ago

Wow it’s really nice concept.


View newTim's profile


554 posts in 2211 days

#3 posted 1096 days ago

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


15670 posts in 2822 days

#4 posted 1095 days ago

Looks much more than “wholly adequate” to me.

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

View AkBob's profile


173 posts in 1151 days

#5 posted 1095 days ago

Beautifully done!

View Don Johnson's profile

Don Johnson

606 posts in 1384 days

#6 posted 1095 days ago

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 (online now)


14842 posts in 1792 days

#7 posted 1095 days ago

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

65 posts in 1173 days

#8 posted 1095 days ago

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


12255 posts in 2701 days

#9 posted 1095 days ago

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


14618 posts in 2280 days

#10 posted 1095 days ago

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

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

View terry603's profile


319 posts in 1517 days

#11 posted 1095 days ago

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

182 posts in 1718 days

#12 posted 1095 days ago

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

-- Dave from "The Sawdust Shed"

View doncutlip's profile


2832 posts in 2160 days

#13 posted 1026 days ago

How do you square the fence to the blade?

-- Don, Royersford, PA

View newTim's profile


554 posts in 2211 days

#14 posted 1025 days ago

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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