How to Build a Crosscut Sled for Your Table Saw

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.

Gathering materials for the crosscut sled

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.

Cutting the base plate of the sled

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.

Creating miter slot guides

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.

Attaching miter slot guides to the sled

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.

Building the front and back fences

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.

Attaching the front and back fences

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.

Making the kerf cut through the sled

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.

Adding final features to the sled

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.

Video

If you found this interesting, please share!