This project was built and designed by Brady Hommel. It’s an easy-to-make crosscut sled designed to improve accuracy and safety for table saw cuts, using basic plywood and minimal tools.
This sled is ideal for anyone looking to upgrade their workflow without spending a lot of time or money. With just a few pieces of scrap plywood and careful setup, Brady demonstrates how to build a highly effective sled for clean, repeatable crosscuts.
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Choosing Materials and Base Size
The core material for this sled is 3/4-inch plywood. You don’t need a full sheet—leftover pieces from previous projects work perfectly, as long as they’re flat and square.
Brady recommends starting with a base size around 18 inches by 14 inches. This provides enough support for most crosscutting tasks without becoming bulky or hard to store.
Cutting the Base
The plywood base is trimmed down in two steps—first cutting to 18 inches wide, then adjusting the saw fence to cut it to 14 inches deep. This approach ensures accuracy while keeping the sled compact and manageable.
A stable base is key to the whole project. Choosing a flat piece of plywood will prevent wobble and help with future alignment when adding fences and runners.
Making the Fence Pieces
The sled includes two fences made from leftover strips of plywood, each cut to roughly 3 inches by 18 inches. These are laminated together to add strength and keep the fence straight.
The rear fence adds stability to the structure and holds the back together. The front fence, which guides your cuts, is the most critical for accuracy and needs to be installed with care.
Fabricating the Runners
Brady uses 1/4-inch plywood for the runners, which slide into the miter slots of the table saw. These strips need to fit snugly without binding or wobbling.
The easiest way to get the right fit is to measure the miter slot at the top and rip the runners slightly oversized, then sand them down gradually. A smooth sliding fit is crucial for the sled’s accuracy and ease of use.
Attaching Runners to the Base
To install the runners, the base is placed directly over the miter slots on the saw, lined up with the fence. Glue is applied to the top of each runner, and the base is set in place.
Weights or clamps help hold everything down while the glue dries. Once set, this creates a precise alignment between the sled and the saw’s miter slots.
Aligning and Attaching the Fences
Once the base is solid, the fences can be glued up and prepared for installation. Brady checks each piece for flatness and uses a level to keep the laminated fences straight.
The back fence is glued and screwed into place first. It doesn’t need to be perfectly square to the blade, but it should be mounted securely to help anchor the structure.
Dialing in the Front Fence
The front fence is where accuracy really matters. It’s positioned using a square and clamped in place before driving in any screws.
Brady advises against gluing the front fence so it can be adjusted or replaced later if needed. A slight gap is left before final tightening to allow for fine-tuning with a square.
Final Cut and Calibration
After the front fence is secured, the blade is raised and the first cut is made through the sled base. This initial cut helps ensure the fence and blade are properly aligned.
Brady suggests checking the sled’s accuracy by making a few test cuts and verifying squareness with a framing or combination square. Minor adjustments can still be made if needed.
Smooth Operation and Safety Tips
To make the sled glide effortlessly, Brady applies polish or wax to the runners and the table surface. This simple step reduces friction and extends the life of both the sled and the saw.
Optional safety features like stop blocks or guards can be added depending on your experience level. For experienced users, simple Sharpie marks can be enough, but new users may want to build in more physical safeguards.
Finishing Touches and Long-Term Use
The final steps involve sanding any sharp edges and making sure all components are flush and comfortable to handle. The result is a clean, lightweight sled that’s easy to carry, store, and use.
This crosscut sled isn’t designed for elaborate joinery or heavy-duty stock, but for everyday tasks and repetitive cuts, it’s an extremely useful shop upgrade. It also serves as a great starter sled for those new to table saw jigs.
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