Looking to enhance your woodworking capabilities? Craftswright has created a fantastic guide to building a custom crosscut sled that you can be proud of. Below, you’ll find a detailed step-by-step tutorial to help you create your own crosscut sled.
Materials & Tools Needed
- 3/4″ Plywood
- 1/2″ Plywood
- Wood Glue
- Clamps
- CA Glue
- Painter’s Tape
- T-Track
- Hold Downs
- Magnets
- Table Saw
- Band Saw
- Router
- Chisel
- Drill
- Screwdriver
- Exact Bench Chisel Set
- Hearing Protection
Step 1: Cut the Base and Front Fence
First, Cody started by cutting the base of the sled from 3/4 inch plywood, followed by the front fence from the same material. This sled is designed primarily for small parts, so a smaller size was chosen. If you’d like to build one yourself, plans are available on the Cody’s website.
Step 2: Create the Miter Slot Runners
While the two halves of the front fence were drying, Cody made the runners for the miter slots, opting for plywood due to its lower susceptibility to humidity changes. The key to making runners is to take it slow and sneak up to the perfect width, ensuring they slide in the slot with no side-to-side slop.
Step 3: Install the Miter Slots
After tilting the blade to 45 degrees, Cody marked the locations for the miter slots. The first miter slot was cut, then moved to the left to mark the second slot. The dado for the removable runner was cut carefully to ensure a tight friction fit.
Step 4: Attach the Second Runner
The second runner is attached by lifting it slightly above the height of the table using handy shims, gluing it with CA glue, and aligning it with the removable runner before securing it in place.
Step 5: Create the Zero-Clearance Insert
Cody opted for a zero-clearance insert made from half-inch plywood. After temporarily holding the fence in place with tape and CA glue, he raised the blade to find where it would hit the fence and marked the area for removal.
Step 6: Cut the Dado for the T-Track
Using a router, Cody cut the dado for the T-track. This approach was chosen for variety, although it could have been done on the table saw. After cutting, a happy accident occurred that required some quick fixes with wood putty.
Step 7: Square the Fence with the Five Cuts Method
The five cuts squaring method made achieving a dead accurate 90-degree fence straightforward. Cody linked to a video explaining this method for those interested in perfecting their sled.
Step 8: Build the Back Fence and Extension Stop Block
The back fence was constructed from 3/4 inch plywood, and an extension arm was made from 1/2 inch plywood. Cody included magnets to hold the extension in place when not in use.
Step 9: Install the Blade Guard
Cody installed a compact blade guard, ensuring safety without adding bulk. After a coat of Osmo Pollux and a fresh paint job, the sled was ready for action.
Final Thoughts
Cody wrapped up the project by considering whether to make a DIY flip stop for the sled. With the new crosscut sled completed, it promises to enhance his woodworking experience significantly.
For more detailed plans go here.