So, after a little kickback scare cross-cutting some 1/2” plywood, I decided to upgrade my cross-cutting sled. The one I have been using sits on only one side of the blade and has just a small fence and no hold downs. This can allow the work to rotate away from the fence and toward the blade (causing the aforementioned scare). After doing some research here and other places on the Net, I found the Super Sled design from the Eagle Lake Woodworking site. I am going to attempt to build it, along with a few refinements I saw from other users here.
I started with pieces of 2’x4’ 1/2” plywood and 1/4” hardboard from my local big box store. That plus some hardware set me back all of $18.00. I am going to laminate the the hardboard to the bottom of the plywood to make the base. I think the smooth side of the hardboard will give me a smoother sliding surface for the bottom of the sled than the plywood alone. I can also rout the 3/4” grooves into the hardboard and the 3/8” grooves into the plywood separately. I went to my local Woodcraft and picked up the T-track for the fence and the jig hardware for the miter attachments. I will be using a 3” x 1-1/4” x 48” piece of red oak for the rear fence and using some red oak cutoffs for the rest of the lumber in the project. I also have some Lexan for the blade guard I am going to add, similar to what others here have done. I will post pictures as the project progresses.
-- Skip, Califormia