Crosscut sled V3.0 - this one's a keeper (with instructions)

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Project by lumberjoe posted 09-23-2013 01:06 AM 5732 views 120 times favorited 19 comments Add to Favorites Watch

Problem – I have a need for a lot of sleds. I like the precision and safety of using them. The issue is they take up a lot of space. I don’t have a lot of space.

The solution ONE sled with replacable zero clearance inserts. Now I get true zero clearance cuts with any blade and any cut.

I made the bottom insert 1/4” and the fence insert 1/2” since it will be taking the full height of the blade.

While this is fairly unique, I can’t take credit. I combined John Nixon’s supersled with an idea I saw in popular woodworking.

I added my usual incra T-Track plus, Miter fence with Incra t track, incra T-Track stops and stop blocks.

A detailed how-to instruction guide can be found here

-- Unplugged Woodworkers -

19 comments so far

View Robsshop's profile


893 posts in 2012 days

#1 posted 09-23-2013 02:37 AM

Very nice looking and functional CC sled. And I agree with You that a good sled is a must have!

-- Rob,Gaithersburg,MD,One mans trash is another mans wood shop treasure ! ;-)

View lumberjoe's profile


2883 posts in 1285 days

#2 posted 09-23-2013 03:08 AM

Thanks. I’m sick of tripping over sleds, so I’d rather have just one that does everything. Also if you only have 1 ZCI per blade, you can trust your kerf lines for cut alignment.

-- Unplugged Woodworkers -

View AngieO's profile


1226 posts in 1184 days

#3 posted 09-23-2013 05:07 AM

This is an awesome sled. Great instructions too. Thanks for sharing.

View Canadian Woodworks's profile

Canadian Woodworks

687 posts in 2107 days

#4 posted 09-23-2013 05:11 AM


-- Paul Lemiski, Ontario Canada, Custom Wooden Rocking chairs and tables

View HuckD's profile


248 posts in 751 days

#5 posted 09-23-2013 05:55 AM

That looks like a great sled! Thanks for sharing all the pictures and instructions.

-- Time is what keeps everything from happening all at once.

View CalgaryGeoff's profile


937 posts in 1519 days

#6 posted 09-23-2013 06:13 AM

Looks like a perfect sled for what you were setting out to accomplish. I like the replaceable zero clearance insert idea and the durable look of the jig.

-- If you believe you can or can not do a thing, you are correct.

View hoss12992's profile


3266 posts in 930 days

#7 posted 09-23-2013 07:56 AM

Great job, love it

-- The Old Rednek Workshop

View Ottacat's profile


381 posts in 889 days

#8 posted 09-23-2013 12:49 PM

Very nice, thanks for sharing.

View MarkTheFiddler's profile


2004 posts in 1226 days

#9 posted 09-23-2013 12:53 PM


Thank you very much Joe! I’m studying your instructions. This will be the second sled you helped me with!

-- Thanks for all the lessons!

View Ken90712's profile


15838 posts in 2226 days

#10 posted 09-23-2013 01:50 PM

Nice sled like your details,,,, I watched a video a yr or two back on this super sled and have thought about making it. Well done should serve you well.

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

View MarkTheFiddler's profile


2004 posts in 1226 days

#11 posted 09-23-2013 04:33 PM

Joe, about the 0 clearance insert. Would it ruin your back fence if you were to make some beveled inserts? I see lots of possibilities but I wouldn’t want to compromise the alignment or stability.

-- Thanks for all the lessons!

View HillbillyShooter's profile


5489 posts in 1329 days

#12 posted 09-23-2013 04:36 PM

Great sled! Now all you need is an insert in the back for different angles that match difference ZCI.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View lumberjoe's profile


2883 posts in 1285 days

#13 posted 09-23-2013 05:17 PM

I have a lot of blank inserts for future bevel cuts.

Mark, the insert in the back fence takes the hit for the bevel cuts. I can cut at a 1” depth (with the gullets above the work piece) before I cut into the actual fence.

That is also why I chose to use 1/2” plywood instead of 1/4” plywood for the fence inserts.

-- Unplugged Woodworkers -

View MarkTheFiddler's profile


2004 posts in 1226 days

#14 posted 09-23-2013 09:36 PM

I can see that now. Thanks Joe!

-- Thanks for all the lessons!

View Matt Przybylski's profile

Matt Przybylski

484 posts in 1415 days

#15 posted 09-23-2013 10:23 PM

This is basically what I planned to do but with a slight modification. I think eventually you will wear out the holes where you screw down and into the bed and the fence with the sacrificial inserts. I was planning on adding either inserts or nuts into those spots and using machine screws to hold the inserts down. Thoughts?

-- Matt, Illinois,

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