A Safer Crosscut Sled

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Project by CueballRosendaul posted 11-25-2013 03:32 AM 5569 views 10 times favorited 5 comments Add to Favorites Watch

Back about a year ago, I built and posted a crosscut sled ( that I built for my table saw. After a year of using it, I experienced a few times where the small pieces I had cut off the end of a board didn’t clear the blade and danced their way into it and launched at me. I had two pieces hit me, and a couple hit the wall, so I decided I better build a typical sled with two sides and bridge boards.

Here’s a short video showing the new and old sleds:

The base is 1/2” oak veneer plywood (in case your wondering why EVERYTHING I make is o.v.p. I have a lot of scrap from a large wainscoting project a few years ago). The bridge/fence is made of some soft maple I salvaged from a pallet. It’s the perfect material because it was 2”x2” after cleaning it up, but it’s very lightweight. The slot runners are made from some hard maple. The second picture shows part of the trick I used for lining them up just right. Since they don’t ride in the bottom of the slot, but only act as a guide, I lifted them up with a few hex nuts in the slot. I ran a thin bead of glue on each runner then with the saw fence in the right spot, I set the base piece down on the runners and put my plumbing toolbox on it to dry for a while. After the glue set up, I added a couple small countersunk screws. I’m amazed that there isn’t any slop at all.

To line up the back fence piece, I ran the blade into the bed about halfway then used my square to ensure that the back fence was 90° to the blade. I ran a heavier bead of glue on the fence piece, clamped it in place, then tapped it into perfect alignment. The finishing touch was a pair of walnut blocks around the back where the blade exits to remind me to keep my thumb out of my crack!

With this new sled and my new Tenryu blade, I’m in shape to make some of those cool cutting boards!

-- Matt CueBall Rosendaul. I don't think I've ever had a cup of coffee that didn't have cat hair or sawdust in it.

5 comments so far

View aussiedave's profile


3114 posts in 1997 days

#1 posted 11-25-2013 11:04 AM

Nice crosscut sled Matt…they are so handy and get lots and lots of use.

-- Dave.......If at first you don’t succeed redefine success....

View Hi_C's profile


56 posts in 1828 days

#2 posted 11-25-2013 01:00 PM

Great Job!....Love the thumb reminders!

View Garry's profile


103 posts in 1889 days

#3 posted 11-25-2013 10:10 PM

Nice job. Tell me about the ruler scale markings. Are they simply made by hand from a rule or did you lay them out more precisely somehow?

-- Garry, North Carolina woodworker and engineer - The journey you're preparing for has already begun.

View CueballRosendaul's profile


484 posts in 2313 days

#4 posted 11-26-2013 06:59 PM

Garry, the markings are simply hand drawn after finish with a fine point Sharpie. They’re not Incra-accurate but they’re close enough. I actually added a set on the other side of the blade as well. I spaced them away from the fence far enough that I can see them without leaning over too far.

-- Matt CueBall Rosendaul. I don't think I've ever had a cup of coffee that didn't have cat hair or sawdust in it.

View Roger's profile


20949 posts in 2977 days

#5 posted 11-27-2013 01:30 PM

Good one, Matt

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

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