LumberJocks

The ultimate crosscut sled

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Project by DanTheLumberJockMan posted 2141 days ago 12491 views 47 times favorited 13 comments Add to Favorites Watch

You can find plans for this in the August 2008 issue of Find Woodworking. I built one so I thought I would share my experience.

The plans are pretty good and for the most part, it went together pretty smoothly. I found the sled easier to make than the sawhorse since the sawhorse requires mortise and tenon joinery. But I used that as an excuse to buy a hollow chisel mortiser :). But you do need to either make this sawhorse or have a fairly large, heavy, sturdy, adjustable one on hand. Since the sled is so heavy, lightweight sawhorses just can’t support it (I tried using some folding plastic ones I have…forget about it)

You’ll also need to order a steel guide bar from onlineMetals.com and be able to tap screw holes. Another excuse to buy another tool. I had never tapped any screw holes before in my life but I found it completely trivial. And I got a cheap tap and die set from HarborFreightUsa.com

The feet on the sled require a taper cut and you know what that means…another excuse to buy another tool ! But you can pick up a taper jig almost anywhere for less than $20 and it really did make these cuts easy.

I didn’t bother with the trapped square nut in the legs. I just used a 4” lag screw. Much easier. I also didn’t see the need to grind down the T-nuts as directed and I didn’t have any problems. I used a store-bought furniture leg for the handle.

One mistake I made…you see the leftmost hole on the back fence? You see how there is no sled underneath it? That’s because when I was measuring for the holes, I forgot the fence overhangs the sled on the left. Watch out for that one!

Precision is key to this project so don’t rush it. Follow the instructions carefully and allow plenty of time to adjust it for perfect squareness and for the Kreg track alignment. But now that it’s all done, cutting large panels couldn’t be easier. The Kreg track allows me to cut without measuring, the sled guarantees a perfectly square cut and the fence minimizes tearout. I would definitely suggest building one of these if you cut lots of large panels as I do for cabinetmaking. Be forewarned though, this is a large project and will take up some shop space. I’m going to figure out a way to hang mine on a wall somewhere when it’s not in use.

-- Dan, San Diego, CA





13 comments so far

View lazyfiremaninTN's profile

lazyfiremaninTN

528 posts in 2557 days


#1 posted 2141 days ago

Beautiful, but man o man, what a monster.

-- Adrian ..... The 11th Commandment...."Thou Shalt Not Buy A Wobble Dado"

View ChuckM's profile

ChuckM

496 posts in 2271 days


#2 posted 2141 days ago

Good work and good review.

Personally I wouldn’t build this cross cut sled jig because my light weight cross cut sled (the usual type) has served me well in the past decade and I don’t foresee any furniture projects that I’m going to do would benefit any significantly from this L-shaped sled at all. May be I’m missing something but the FW article didn’t convince me this project was for my shop. If I ever need to cross cut a huge board that my tablesaw and current jig couldn’t handle, I simply call upon my shop-tested tools – the circular saw and the ripping jig built for that purpose.

-- The time I enjoy wasting is not time wasted

View Cov's profile

Cov

49 posts in 2151 days


#3 posted 2140 days ago

Great job, I read the article it appears you are spot on. It would be nice to have one for cabinets.

-- Cov, Loomis, CA, http://www.covingtonwoodworks.com

View Chris 's profile

Chris

1867 posts in 2595 days


#4 posted 2140 days ago

I had been wondering how long it would it might be until a jock posted one of these sleds… Nice work and thanks for the links to your sources….

-- "Everything that is great and inspiring is created by the individual who labors in freedom" -- Albert Einstein

View tenontim's profile

tenontim

2131 posts in 2348 days


#5 posted 2140 days ago

Nice job. Of course, being left handed, I would build it flipped over. Then I wouldn’t need the support. I never could figure out why people would cross cut lumber on that side of the blade, when you have that big side table to support your work. Oh, well, to each his own. Thanks for the post.

View Rasim Ramadan's profile

Rasim Ramadan

75 posts in 2199 days


#6 posted 2140 days ago

Thats soooo big

View Jerry's profile

Jerry

209 posts in 2143 days


#7 posted 2140 days ago

Great job!! I have a much smaller sled that works great until I started doing cabinets. Thanks for the pics and the great information.

-- Jerry - Rochester, MN *Whether you think you can or you can't, you are probably right* - Henry Ford

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 2904 days


#8 posted 2139 days ago

Very impressive, if I only had room for this, I wish.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1

View PaBull's profile

PaBull

928 posts in 2269 days


#9 posted 2135 days ago

Very nice, and you build the stand also from the same article…

-- rhykenologist and plant grower

View woody57's profile

woody57

645 posts in 2031 days


#10 posted 2023 days ago

What is the cross cut capacity of this sled. I made one recently using a different design and I can cut a piece 36” wide. I may trash mine and build this one if the capacity is more.

-- Emmett, from Georgia

View Beginningwoodworker's profile

Beginningwoodworker

13337 posts in 2277 days


#11 posted 1814 days ago

Thats a beautiful crosscut sled.

-- CJIII Future cabinetmaker

View WoodNuts's profile

WoodNuts

74 posts in 1552 days


#12 posted 1422 days ago

I like the saw horse; its very similar to one Charles Neil has on his TS safety YouTube video. Did you follow a plan for that? Are you using mini tracks for the riser channels? Do you have dimensions/plans?

-- ...there's a fix fer dat...

View BBrown626's profile

BBrown626

32 posts in 565 days


#13 posted 150 days ago

I am curious if you are still using this sled? Any improvements made to it?

I recently sold my sliding table saw to buy a conventional saw and miss the panel cutting capabilities.

I was thinking of making one, but for the support I thought possibly a steel pipe (DOM Tube?) and maybe helping the sled glide across it by fitting some skateboard bearings.

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