Looking for a fun way to create a functional and efficient crosscut sled? This project was designed and built by Bourbon Moth Woodworking, and it’s perfect for woodworkers of all skill levels. With just a few materials and tools, anyone can follow along and create a custom sled tailored to their needs.

Materials & Tools Needed:
- (1) 4×8 sheet of plywood (scraps)
- (1) Aluminum T-Track
- (2) Hold Down Clamps
- (1) Hard Maple (for miter slot guides)
- (1) Extruded Aluminum (for front fence)
- (1) CA Glue
- (1) Accelerator Spray
- (1) Tape Measure
- (1) Router
- (1) Table Saw
- (1) Miter Saw
- (1) Clamps
- (1) Safety Glasses
Step 1: Gather Your Materials
Before starting, Jason emphasizes the importance of having materials on hand. In this case, the creator had a ridiculous amount of plywood scraps, which is perfect for building the sled. The first task is to locate a T-Track, as this will allow the sled to slide back and forth smoothly.
Step 2: Cut the Base Plate
Using a sheet of pre-finished birch plywood, the creator cut out the base plate for the crosscut sled. The surface is slick, which is ideal for sliding on the table saw. The base was trimmed to size with a miter saw for convenience.
Step 3: Create Miter Slot Guides
Next, Jason searched for hard maple to create the miter slot guides. After finding the right piece, the guides were cut to fit snugly into the sled, allowing for smooth movement without resistance.
Step 4: Attach the Miter Slot Guides
Once the guides were cut, they were attached to the sled base using CA glue and accelerator spray. To ensure they stayed in place, the creator added countersunk screws for extra security.
Step 5: Build the Front and Back Fences
The next step involved constructing the front and back fences. The creator decided to use aluminum for the front fence while laminating plywood for strength. The combination of materials ensures durability and functionality.
Step 6: Attach the Fences
After cutting the fence pieces to size, the creator attached them to the sled. The back fence was secured over the kerf, while the front fence needed to be square to the blade, allowing for precise cuts.
Step 7: Make the Kerf Cut
With the sled fully assembled, it was time for the kerf cut. The blade was raised through the sled to create a zero-clearance kerf, ensuring clean cuts every time.
Step 8: Final Adjustments and Features
The final touches involved adding T-Tracks to the sled’s surface for hold down clamps, which enhance safety and precision. The creator also ensured the sled was perfectly square to the blade, making adjustments easy if needed.
Conclusion
There you have it! A fully functional crosscut sled made from materials found around the shop. Jason successfully created a versatile tool that not only improves safety but also enhances the accuracy of cuts. For anyone looking to improve their woodworking projects, this sled is a must-have.