| Project by ytsejamr | posted 481 days ago | 3773 views | 45 times favorited | 36 comments | ![]() |
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Let me start this out by saying I am fully aware that this thing is overkill. I wanted to make a crosscut sled that I would be proud of and last a long time. I had a couple leftover walnut boards from my columns that I ended up using: 
I used some cheap Borg plywood, Kreg T-track, and the Kreg runners. I really like the runners. The sled is about the size of my table saw top. The maple pieces were scrap also.
I had the bright idea of embedding a tape rule near the fence and then covering it with poly. It didn’t quite turn out like I had expected. I routed a shallow channel for the tape, put it down, taped it off and poured poly in. In hindsight, I should have used epoxy. I also had some issues with the top. I was playing with tinted shellac. I didn’t put it down very evenly on the base, so I tried sanding it off. Well, when I did that I sanded through to the tape in a couple spots. The tint really got into the grain of the plywood, and if I sanded any further I would have been through. So the top doesn’t look all that great, but it’s still functional.
I added a lexan blade guard. It’s screwed in, so I can remove if I need to.
All in all, I’m pretty happy with it. It’s a little heavy . . . but I can handle it. :-)
Here’s a shot of squaring up the fence before screwing it down. 
I ended up using the 5-cut method to fine tune the fence just a bit. It’s been solid ever since.
And a few other shots:



-Brian































36 comments so far
SteveKorz
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2030 posts in 605 days
posted 481 days ago
I don’t think this is overkill, I think it’s craftsmanship!... Very nice, great job on this!
-- As iron sharpens iron, so one man sharpens another. (Proverbs 27:17) †
TedM
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1840 posts in 624 days
posted 481 days ago
Very nice!
-- I'm a wood magician... I can turn fine lumber into firewood before your very eyes! - http://www.woodworkersguide.com
wpreman
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1486 posts in 604 days
posted 481 days ago
I agree with Steve, nicely done!
-- Bill, Florida
sIKE
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1094 posts in 645 days
posted 481 days ago
Man this thing is a beaut! At first glance, I was thinking nice, but I want a tape on my next one. Then you did the unexpected! You put the tape on the table itself! Brilliant! Consider that idea leeched! The blade guard in the back is very perty! Very impressive.
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
Bigdogs117
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1799 posts in 512 days
posted 481 days ago
Very Sharp….I agree with Steve, beautiful craftmanship using leftovers.
-- Rusty
KRAIG
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8 posts in 912 days
posted 481 days ago
GREAT JOB. USE MINE ALL THE TIME.
-- kraig stewart
Greg Wurst
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716 posts in 724 days
posted 481 days ago
Fancy!
-- You're a unique and special person, just like everyone else.
depictureboy
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305 posts in 534 days
posted 481 days ago
Very nice, I have been holding off on making a sled for a bit, I found a nice one in shopnotes with a sliding section that makes it an adjustable zero clearance insert…but the design was for a right tilt table, so I have to modify it for mine, plus get the plywood etc…so its a process…yours is absolutely beautiful, and it includes several of my thoughts as far as what makes a nice sled.
Great Work!
-- If you can't build it, code it. If you can't code it, build it. But always ALWAYS take a picture.
SawdustMill
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65 posts in 624 days
posted 481 days ago
heh, “fancy” is an understatement :)
Quentin
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43 posts in 1038 days
posted 481 days ago
I love it!
ytsejamr
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50 posts in 487 days
posted 481 days ago
“Man this thing is a beaut! At first glance, I was thinking nice, but I want a tape on my next one. Then you did the unexpected! You put the tape on the table itself! Brilliant! Consider that idea leeched! The blade guard in the back is very perty! Very impressive.”
Here’s a tip. Make sure you route the channel for the tape before you put the back fence on. I didn’t thinking I could get a palm router in there close to the fence, but it wasn’t going to happen. I ended up taking the back fence off, then trying to route the channel in the plywood that already had the saw cut through it. Then I had to re-square the fence. So yeah . . . route that channel first! :-)
sIKE
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1094 posts in 645 days
posted 481 days ago
Thanks! That is a great tip!
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
Texasgaloot
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467 posts in 592 days
posted 481 days ago
I figure that 100 years ago craftsman showed off their abilities through the tools they made for themselves in the workshop. Why should today be any different, just because the tools have tails? I think it makes a great sales brochure! Great job!
-- There's no tool like an old tool...
Garyb6
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262 posts in 522 days
posted 481 days ago
Nice sled. I agree with the others. Make your shop fixtures as nice as you would any other item you build.
-- Garyb6, “Make everything as simple as possible, but not simpler” - Albert Einstein
Chris
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1462 posts in 883 days
posted 481 days ago
Looks Great! There is no such thing as overkill when it comes to a sled….
You should see the one I just finished :) Yours seems a lot sleeker and more refined than mine.
!
!
-- Chris
jcees
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553 posts in 691 days
posted 479 days ago
Lovely sled. It will always, always, make you smile to use it and if that ain’t reason enough to make one, then…
always,
J.C.
-- "Imagination is more important than knowledge" -- Albert Einstein
kolwdwrkr
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2244 posts in 482 days
posted 479 days ago
do you use that thing or hang it on the wall above the saw to look at? LOL. Very nice.
-- ~ Inspiring those who inspire me ~
sIKE
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1094 posts in 645 days
posted 479 days ago
Are you using a 2 Tapes 1 L2R and the other R2L?
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
ytsejamr
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50 posts in 487 days
posted 478 days ago
“Are you using a 2 Tapes 1 L2R and the other R2L?”
Yup . . . you’ve got it.
sIKE
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1094 posts in 645 days
posted 478 days ago
So, just to make sure I have the process correct. Route grove for tapes into table, set and square fence, run blade into table. Now place the tapes into routed groves an epoxy it in.
Is this correct?
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
sIKE
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1094 posts in 645 days
posted 478 days ago
So, just to make sure I have the process correct. Route grove for tapes into table, set and square fence, run blade into table. Now place the tapes into routed groves an epoxy it in.
Is this correct?
-- //FC - Round Rock, TX - "Experience is what you get just after you need it"
ytsejamr
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50 posts in 487 days
posted 478 days ago
Yeah, that sounds about right. The order might change a bit depending on how you set and square the fence. I used Niki’s method of setting the fence, which involves putting the blade through the table, and then setting the fence. The key part is to route the groove first. Then once the blade is through the table and the fence is on, you’re able to put the tape in.
Michael Brailsford
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212 posts in 485 days
posted 477 days ago
Who says jigs need to look utilitarian? Nice work.
-- Michael A. Brailsford
Tim Dorcas
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130 posts in 750 days
posted 435 days ago
I just found this by accident but I’m glad I did. Very impressive.
-- www.responsetolight.com - A Woodworking & Renovation Blog & www.craftedbytim.com - I make. You buy.
cabinetmaster
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8461 posts in 450 days
posted 435 days ago
Beautiful crosscut sled. You did an excellent job and you’ll get many years of use from that one. Some really neat things you did there. By the way, how do you like that grizzly saw? It looks like the one I had when I had my own cabinet shop. Wish I had not sold it.
-- Jerry--A man can never have enough tools or clamps
ytsejamr
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50 posts in 487 days
posted 421 days ago
I love the grizzly saw! Although, I don’t have much to compare it to other than my old underpowered craftsman 7 1/4” table saw. But yeah, no complaints from me.
Brad
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87 posts in 665 days
posted 406 days ago
What is the “Five Cut Method” you mentioned for fine tuning up the sled?
THanks,
Brad
-- Great Coffee= 8oz strong coffee, 1tbsp brown sugar, 1tbsp 1/2&1/2, 1 heaping teaspoon mahoganny
AgentTwitch
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34 posts in 388 days
posted 388 days ago
a Maloof inspired cross-cut sled! hehehe
Looks great and comfortable to use for lots of cross cuts.
-- Regards, Norm
ytsejamr
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50 posts in 487 days
posted 360 days ago
5-cut method . . .
http://www.thewoodshop.20m.com/five_cut_method_swf.htm
Sorry for the late reply . . . haven’t been to lumberjocks in a while.
woodworm
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8135 posts in 482 days
posted 360 days ago
Truly fancy sled, great effort!
Do not blame yourself for overdoing it. That is normal a woodworker would do more than he/she should do.
-- masrol, kuala lumpur, MY.
Todd Thomas
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4827 posts in 340 days
posted 298 days ago
wow…great looking sled…..very nice
-- Todd, Oak Ridge, TN, Hello my name is Todd and I'm a Toolholic, I bought my last tool 10 days, no 4 days, oh heck I bought a tool on the way here! †
David_Bethune
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243 posts in 285 days
posted 250 days ago
Sweet. I think you should make another one and send it to me..:)
Chris
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300 posts in 249 days
posted 248 days ago
I’m with Dave; ship me one too. Very nice. I just looked over the rest of your projects and I can say one thing for sure – you don’t go halfway on stuff. It’s not too fancy, and should make you feel good every time you take it out for a cut.
-- Chris
Snoop
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19 posts in 302 days
posted 228 days ago
This sled is awesome. Since I’m sure you use the sled a lot it sure is a bonus that it is so easy on the eyes as well.
-- "Whether you think you can, or whether you think you can't, you're right."
topspin
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23 posts in 310 days
posted 212 days ago
That’s a sweet sled. Do you have another you use when you need to do a cut with the blade tilted… wouldn’t want to mess up that base of rear fence…
-- Seems that talent only gets you so far... effort makes you successful.
Kent Shepherd
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805 posts in 178 days
posted 171 days ago
It was great jigs like this that inspired me to build beautiful, as well as functional pieces. i saw it long before I joined. Thanks for sharing. You raised the standard a few notches.
-- Kent Shepherd * The goal is-----More Tools!