Are you looking to improve your table saw cuts? In this tutorial, we will be crafting a simple yet effective crosscut sled designed by Steve Ramsey from Woodworking for Mere Mortals. This project will help you achieve accurate, repeatable cuts.
Materials & Tools
- (1) 3/4″ plywood for the sled base
- (2) runners (made from quarter-inch plywood or hardboard)
- (2) 2.5″ wide strips of 3/4″ plywood for the fences
- Wood glue
- Clamps
- Hand saw
- Table saw
- Finishing wax for sliding ease
Step 1: Understanding the Need for a Crosscut Sled
The crosscut sled is a solution to the limitations of standard miter gauges that come with most table saws. Miter gauges can be inaccurate and leave boards unsupported, leading to poor cuts. A crosscut sled provides stability, accuracy, and cleaner cuts.
Step 2: Making the Runners
Start by creating runners that will fit snugly into your table saw’s miter slots. It’s important that they fit well—neither too tight nor too loose. You can use quarter-inch plywood or hardboard for this purpose. Avoid using solid wood, as it may expand and contract with humidity.
Step 3: Constructing the Sled Base
For the sled base, cut a piece of 3/4″ plywood to size. A common size is 16″ by 30″, but you can adjust it based on your needs. Glue the runners to the bottom of the sled base, ensuring they are slightly proud of the surface for proper alignment.
Step 4: Attaching the Runners
Once the glue has dried, test the sled by sliding it on the runners. It’s crucial that the sled moves smoothly without any binding. If needed, trim the ends of the runners to ensure a flush fit.
Step 5: Creating the Fences
Next, cut two strips of plywood for the front and back fences. Glue these strips together and then clamp them until dry. After they are dry, square them off and cut them to the same width as the sled.
Step 6: Installing the Rear Fence
Glue the rear fence into place. It doesn’t necessarily need to be square to the blade, but squaring it can help with overall accuracy. Use a square to align it with the blade, and once it’s set, clamp it down.
Step 7: Setting the Front Fence
Now, install the front fence. This part is crucial—it needs to be exactly 90 degrees to the blade. Use a square to check the alignment and make adjustments as necessary before securing it in place with screws.
Step 8: Adding Safety Features
Cut strips for safety features that will help keep your fingers at a safe distance from the blade. These should be mounted in a way that they won’t interfere with the sled’s operation.
Step 9: Finishing Touches
Finally, apply paste finishing wax to the runners and the bottom of the sled to ensure smooth sliding. Let it dry for about 10 minutes before buffing it off.
And there you have it! Your very own crosscut sled that will enhance your woodworking projects by providing precise, safe cuts. For more detailed plans and resources, visit myshopjigs.com.