Looking for a simple and effective crosscut sled for your table saw? This straightforward design was created by Brady Hommel from the Brady Hommel channel, and it can be built in just a few minutes.
Materials & Tools
- (1) Sheet of 3/4″ plywood
- (1) Sheet of 1/4″ plywood for runners
- Wood glue
- Screws (1 5/8″ drywall screws recommended)
- Saw (table saw recommended)
- Square
- Level
- Sanding block or hand sander
- Wax or furniture polish (optional)
Step 1: Determine the Size of Your Sled Base
Your first step is to determine the size of the base of your sled. It’s common to make it too big, so aim for a smaller size. For this project, we’re going with an 18″ by 14″ base. Start by cutting your plywood to 18″ wide, then adjust your table saw fence to 14″ and make the second cut.
Step 2: Cut the Fence Pieces
Next, cut four pieces measuring 3″ by 18″ from the same plywood. These will serve as the fences for your sled.
Step 3: Create the Runners
For the runners, use 1/4″ plywood. Measure the grooves in your table saw to ensure a snug fit. Cut the runners to about 3/4″ wide, adjusting as necessary for a perfect fit.
Step 4: Glue the Runners to the Base
Once your runners are cut, apply glue and position them on the base. Use pennies to elevate the runners slightly above the table surface for easier glue application. Place the sled base against the fence to ensure alignment and apply some weight to set the glue.
Step 5: Assemble the Fences
While the runners dry, glue the fence pieces together using a level to keep them straight. Let these glue-ups cure completely, or for a quicker option, glue and screw them together.
Step 6: Attach the Back Fence
Once the glue has dried, trim the excess length from the runners. Then, glue the back fence onto the sled base, ensuring it doesn’t interfere with the blade’s path.
Step 7: Attach the Front Fence
Now it’s time for the front fence, which is crucial for accuracy. Raise the blade and temporarily clamp the front fence in place. Use a square to align it properly with the blade, then secure it with screws.
Step 8: Final Adjustments
After securing the front fence, test the sled’s movement and ensure everything is square. If adjustments are needed, unscrew and reposition as necessary.
Step 9: Waxing the Sled
To ensure smooth movement, apply wax or furniture polish to the bottom of the sled and the table saw bed. Buff it until smooth to enhance glide.
Step 10: Test Your Sled
Finally, raise the blade and cut through the front fence to complete the kerf. Test the sled with a piece of wood to ensure it cuts accurately.
With these steps, you now have a simple and effective crosscut sled for your table saw.
Video