College of the Sequoias Crosscut Sled.

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Project by 559dustdesigns posted 05-05-2012 08:48 AM 24226 views 78 times favorited 19 comments Add to Favorites Watch

Here is my version of John W. Nixon’s Super Sled. I started this cross cut sled while attending my fourth semester at the Collage of the Sequoias cabinetmaking class which was more than a year ago. I wanted to build a sled that would help my fellow students cross cut large sheet goods safer. The instructors stress and demonstrate the proper way to safely cross cut boards, but there are still some sketchy close calls. This Wadkin Bursgreen table saw (one of two set up in the shop) has a very large table built around it for better out feed and crosscut support. This 14” saw (with a 12” blade installed) is set up mainly for cutting sheet goods, it’s tilt hand wheel has been removed to ensure the saw will always cut at 90 deg.

I started this project by laying out the base which is made of 1/2” Baltic Birch plywood. I designed the large base to support larger boards to the left side of the blade. I also added two small tee slots on this section of the sled a one of the many changes I made to John’s design. The large main fence is made of special reclaimed Old Growth Doug Fur that was donated to the college. The sled uses Incra miter sliders which can be adjusted through holes drilled in the base. This worked great to adjust the sliders in the saw’s miter slots. Below are pictures of the fence stop and one of the three hold down clamps that were made from scraps of red oak and some hardware.

The stop block can be placed anywhere along to main fence making repeatable cuts easy.
The hold down clamps are used to hold the wood against the fence and the base of the sled while making safer cuts.
The sled has a removable blade guard with a Lexan window. The large handles attached to the fence give the operator good control over the sled. The rear guard with it’s curved Lexan window, is designed so that the operator could never cut too deep. The sled is limited by the miter slots milled in to the out feed support it would be impossible to cut through the rear guard.

While building some of the final details. I utilized a video posted by William NG his video shows how to check your cross cut sled for square. His post called 5 Cuts to a perfect Cross Cut Sled also shows how he adjusts his sled to get really accurate cross cuts.

I got a surprise, after making 5 quick cuts my Sled was exactly “perfect”, honestly I don’t usually have things go this well. When the sled and accessories were finished the Cross Cut Sled needed a place to “hang around.” I decided to build a rack to hang my sled and its accessories on while not in use.

I am proud of this project and I did my best to design and build a Safe Cross Cut Sled that should last for a long time.

-- Aaron - central California "If you haven't got the time to do it right, when will you find the time to do it over?"

19 comments so far

View Jamie Speirs's profile

Jamie Speirs

4168 posts in 3090 days

#1 posted 05-05-2012 08:58 AM

That is a nice Sled

I’m sure it will get lots of use.


-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View Ken90712's profile


17614 posts in 3423 days

#2 posted 05-05-2012 10:08 AM

Great sled and storage well done. i just made one a while back and used the same 5 cut test and set up. Well done.

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

View Martyroc's profile


2712 posts in 2540 days

#3 posted 05-05-2012 10:52 AM

That’s a great sled, I like the design of this very much. Great job

-- Martin ....always count the number of fingers you have before, and after using the saw.

View Bsmith's profile


330 posts in 2904 days

#4 posted 05-05-2012 12:29 PM

Great job! A good cross cut sled is my next project.

-- Bryan

View grumpy749's profile


228 posts in 2611 days

#5 posted 05-05-2012 01:59 PM

WOW… This is by far and away the very best table saw/out feed set up I have ever seen… envious ! Great looking sled as well, nice and safe.

-- Denis in Grande Prairie. Yesterday is history, tomorrow is a mistery, but today is a gift. That is why it is called the present.....Pink !

View Dan Krager's profile

Dan Krager

4224 posts in 2468 days

#6 posted 05-05-2012 03:10 PM

I especially like the storage thought. Most jigs seem not to have a home. They are the homeless of the woodworking world.

-- Dan Krager, Olney IL Now there's a face that would stop a clock! And seriously mess with small watches.

View OutPutter's profile


1199 posts in 4224 days

#7 posted 05-05-2012 03:23 PM

You did a great job on the sled. I’m sure it will serve you well in the future. One small nit to pick – the itsiebitsie pictures make it just a little hard to fully appreciate.

-- Jim

View Bob817's profile


674 posts in 2616 days

#8 posted 05-05-2012 05:25 PM

That sure is one super sled…...NICE!

-- ~ Bob ~ Newton, N.H.

View steliart's profile


2891 posts in 2922 days

#9 posted 05-05-2012 08:01 PM

Excellent sled

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions !!!

View eddie's profile


8565 posts in 2848 days

#10 posted 05-05-2012 09:45 PM

a safe sled ,great build of the super sled Arron

-- Jesus Is Alright with me

View NormG's profile


6375 posts in 3238 days

#11 posted 05-05-2012 11:52 PM

Wow, great sled

-- Norman - I never never make a mistake, I just change the design.

View dnick's profile


986 posts in 2616 days

#12 posted 05-06-2012 03:44 AM

I don’t believe I’ve seen a better sled. Nice job.

-- dnick, North Hollywood, Ca.

View thedude50's profile


3605 posts in 2712 days

#13 posted 05-06-2012 08:45 AM

Hey buddy nice sled you have done Visalia California. Proud SO how about we get together and you can show me how you did this I would like to draw it up in sketchup and Make one that will fit my saw. PM Me and lets try to get together.5 out of 5 stars on this sled

-- Please check out my new stores and

View dragonnotes's profile


82 posts in 3266 days

#14 posted 05-06-2012 12:08 PM

Very nice. You never really think of the storage, until after it’s too big to fit anywhere. Very well done. Bravo. Keep up the good work and remember to always enjoy what you do.

View davidroberts's profile


1027 posts in 3720 days

#15 posted 05-07-2012 03:20 AM

Your cross cut sled is the full package. Don’t think I’ve seen one quite that well thought out. I know you used ideas from others and made improvements, but man, you really knocked it out of the ballpark. And that English arn Watkins ain’t to shabby either. Would not mind bellying up to that machine for a crosscut or two.

-- Better woodworking through old hand tools.

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