The video “Have a Table Saw? You NEED to do This!!!” is by Biscuit Tree Woodworks. In this guide, Biscuit Tree Woodworks shares the essential steps and tips for constructing a crosscut sled that enhances the capabilities of any table saw.
Why a Crosscut Sled?
A well-made crosscut sled is an invaluable addition to any woodworking shop. It provides precision and repeatability far superior to the standard miter gauge that often comes with table saws. The sled’s fence allows for perfectly square cuts, and with a stop block, users can quickly produce multiple parts of the exact same length. Biscuit Tree Woodworks points out that his old sled, which he picked up at a yard sale, had several flaws that he aimed to correct with this new build.
Identifying the Problems
His previous sled was too big and heavy, making it impractical for everyday use. The melamine top was too slippery, causing workpieces to slide during cuts, which not only affected accuracy but also posed a safety risk. Additionally, the built-in stop block had too much flex, leading to inaccurate results when pressure was applied. This new build aims to resolve all these issues.
Materials and Initial Cuts
Biscuit Tree Woodworks begins with a three-quarter inch sheet of plywood, cutting it down to 36 by 24 inches for the sled’s base. Several thinner strips are also cut for the front and back fences. Once all pieces are cut, he proceeds to glue up the parts for the fences.
Creating Straight Fences
Plywood can bow, which can lead to inaccuracies. To combat this, he flips one piece of plywood around to oppose the bow while clamping it down to a flat surface—specifically, the front rail of his table saw, which is solid steel and dead flat. This ensures a perfectly straight and true fence.
Finishing the Fences
After the glue dries, he runs one edge over the jointer to ensure the fences are square, followed by cleaning up the other side at the table saw. The ends are trimmed at the miter saw, and sharp edges are rounded over using a router table.
To prevent dust from interfering with cuts, he uses a block plane to create a small chamfer on the inside edge of the front fence. This chamfer allows dust to escape instead of getting wedged between the wood and the fence, ensuring accurate cuts.
Installing T-Track and Miter Bars
Next, Biscuit Tree Woodworks installs a piece of t-track in the fence for attaching a stop block. He sets the height of his router bit accordingly to cut a groove into the fence. After trimming the aluminum t-track to size, he prepares to install miter bars.
Choosing Miter Bars
This time, he opts for aluminum miter bars instead of hardwood. Aluminum bars won’t swell or shrink with humidity changes, ensuring consistent performance. They are also reusable, which is advantageous for future sled builds.
Assembly and Fence Alignment
After installing the miter bars, he temporarily binds them with CA glue before flipping the sled to secure them with screws. The rear fence is attached with glue only, while the front fence is aligned as accurately as possible before being clamped and secured with screws.
Checking for Accuracy
To ensure the sled is accurate, he employs the William Ing 5 cut method. This involves making several cuts and measuring discrepancies to adjust the alignment of the fence.
After taking measurements, he discovers that his fence needs to be adjusted by a mere 13 thousandths of an inch to achieve perfect alignment. He carefully pivots the fence to make this adjustment.
Final Adjustments and Safety Features
With the adjustments complete, he drills additional pilot holes to secure the fence firmly. To enhance safety, he creates a block on the back of the sled to keep hands clear of the blade.
Upgrading the Stop Block
For the stop block, he chooses the Katz Moses stop block, known for its efficiency and aesthetics. Biscuit Tree Woodworks emphasizes that while a simple block of wood can work, the upgraded stop block provides superior functionality.
Conclusion
This sled not only improves the accuracy of cuts but also enhances the overall experience of using the table saw.