Reply by MarkTheFiddler

Thanks to everyone! You all are awesome,

After reviewing your diagnosis and suggestions. I have come to a conclusion – the only thing I did correctly was use some maple (in the wrong place).

Earlier, I very confidently stated that the only part I did right was use metal for the tracks or rails. That’s fine and good but the rails are too small both depth and widthwise. I believe that was my final piece of denial that I had built a lousy tray for a hotdog vendor.

The good news is that I used left over materials and I’m out of pocket for a few bolts and nuts.

I also laid out some decent pretty cash for bits that would drill holes and countersinks in my metal tracks. I can’t complain too much because now I have what I feel is my best set of bits. Kobalt, titanium quickchange. (Unfortunately – I wasn’t as sensitive to the made in China philosophy here at LumberJocks. I understand your valid points and I’ll buy USA as often as humanly possible.)

After following a few suggested links in this post and using your information, I know that I will need to make new tracks from maple. I know how to set them just right. I know how to set the front and back correctly. I know how I’m going to prevent cracking. I know what materials to use for the base. I understand what a kerf is and how important it is to get it right. I know how to lubricate the thing.

Do I know everything I should know about this? Heck no. As a matter of a fact, my second crosscut sled will be good only for crosscuts up to a 2×4 depth. I’m going to keep it simple enough so I can do a good job with it and get it set for the project in my blog. I’ll learn about the bells and whistles (I suppose you can say built-in adjustable jigs) as I need them and put them on my third iteration.

And now a quick confession – I try to figure things out on my own. When I “think” I have the picture, I go with it. I think that is my main issue with woodworking. I suppose I learn better from my failures because then I am real open minded about finding the resources and following them. It’s not a good excuse though, It just more or less guarantees that I will ruin everything on my first attempt. One of you has a really cool signature that says “Woodworking – Patience = Firewood”. I get it. I hope I can change.

-- Learning is like a door. Open it and there are hundreds more on the other side. Thanks for all the lessons!