Tablesaw Crosscut Sled

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Project by vrice posted 294 days ago 2103 views 32 times favorited 12 comments Add to Favorites Watch

Yeah, we see numerous crosscut sleds posted here. I’ve made several myself. I wanted to post this one because I am finding this particular design makes it REALLY easy to keep the fence absolutely square AND with the removable extension I can make a cut on the sled up to 65” in length, with the stop. That’s pretty useful, in my shop.

This sled is from a very recent ShopNotes, vol. 22 issue 130. The second shot shows the design of the runner system. That is each of the two runners (my are from phenolic stock) is attached with 4 machine screws. The runners have holes tapped for the 1/4”-20 machine screws. The holes in the sled base for the screws are over sized, 3/8” holes. This gives a fair amount of slop such that you can place the sled on the saw with the 8 screws loosened, adjust the whole sled back and forth until you have a perfectly square fence, then simply tighten the 8 screws. Dead simple.

This thing also has a removable fence extension. The extension has a hardwood (mine is walnut) key that sits in a dado on the base fence, being fastened via two 1/4”-20 knobs that screw into threaded inserts on the base. Solid. This gives a cutting capacity of 65”, with the included stop. The stop simply rides in T-track installed in the fence and the fence extension.

Lastly, the other feature I really like on this sled is the replaceable zero clearance insert. This was always an issue with my other sleds, after I had switched blades a few times or more drastically used it for dado cuts. Not now.

-- Vic Rice

12 comments so far

View TopamaxSurvivor's profile


14604 posts in 2276 days

#1 posted 294 days ago

Very nice sled. Is the ZCI hardboard?

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

View eddie's profile


7013 posts in 1215 days

#2 posted 294 days ago

sweet sled

-- Jesus Is Alright with me

View archwwc's profile


8 posts in 547 days

#3 posted 294 days ago

Very cool sled. I’m building one right now based off of John Nixon (Eagle Lake Woodworking) Super Sled. I do like the attachment of yours. Do you find that the weight of the board you are cutting makes it hard to slide on the table saw or messes with the squareness?

View Henry Mowry's profile

Henry Mowry

182 posts in 1668 days

#4 posted 294 days ago

I’ve already had that issue of Shopsmith pulled … this sled is a must to do!

-- Henry Mowry, Santa Clarita, CA,

View CharlesA's profile


1074 posts in 398 days

#5 posted 293 days ago

I built this one as well. I really like it for repeatable length crosscuts. Why did you put a big block on the front?

View BArnold's profile


170 posts in 433 days

#6 posted 293 days ago

Excellent implementation of the ShopNotes design, Vic! When I saw it in the recent issue, I thought it would be a good update to the very simple crosscut sled I made years ago. You did good!!!

-- Bill, Thomasville, GA

View lumberjoe's profile


2829 posts in 849 days

#7 posted 293 days ago

I love the replaceable zero clearance inserts on my sled.. One suggestion would be to add a removable piece to the rear fence as well.


View vrice's profile


72 posts in 1292 days

#8 posted 292 days ago

Thanks for the comments everyone. Let me address all the questions here:
1. Yes the ZCI is hardboard, 1/8”.
2. No I have not found long boards cause a problem. I do regularly apply paste wax to the bottom. I have not seen any effect on my ability to maintain squareness. In fact I have been quite impressed with how well it has maintained. Been using for several weeks now and the squareness is still spot on. Hope it stays that way…....
3. The big block is protection against me being an idiot. Specifically it protects my hands for the spinning blade as it would protrude from the back. I had some scrap 12 quarter basswood. So I cut a chunk of that to size and just glued it to the back. Now the blade can’t get me.
4. Yes, I did notice that a ZCI on the fence would be nice. Oh well. Yours looks good.

-- Vic Rice

View Gib's profile


5 posts in 164 days

#9 posted 132 days ago

I was browsing through some back issues of Shop Notes recently, and noticed this sled as well. I was wondering where to buy the phenolic for the runners. I can’t seem to find a source. Any advice?

-- -Gib, Kansas City, MO. Amateur woodworker & owner of One Tiny House -

View CharlesA's profile


1074 posts in 398 days

#10 posted 132 days ago

The phenolic I bought for this use some time ago has a tendency to twist when cut, so I just use hardwood and wax and it works quite well.

View CharlesA's profile


1074 posts in 398 days

#11 posted 132 days ago

double post. nm

View vrice's profile


72 posts in 1292 days

#12 posted 132 days ago

I used the source listed in the ShopNotes article. You can find it here.

-- Vic Rice

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