This small parts crosscut sled, complete with an adjustable stop and a miter attachment, was designed and built by DIY Montreal.
Materials
- 3/4 inch plywood
- Polyethylene runner
- T-track
- Closet bolts (5/16)
- Star knobs (5/16)
- Washers (5/16)
- #8 Flat Head screws
- #6 Flat Head screws
- Krazy Glue
- Paste Wax
Tools
- Table saw
- Router table (or table saw for dado cuts)
- Drill
- Clamps
- Screwdriver
- Speed square
- Combination square
- Pencil
Step 1: Prepare the Base
Start with a piece of 3/4 inch plywood. Mark the center on the top side, then flip it over to make additional markings for later use.
Step 2: Install the Runners
At your table saw, position the fence so the center marking aligns with the blade. Secure the fence and remove the board to install the runners. Use a polyethylene runner, which offers smooth movement and durability against temperature changes.
Step 3: Attach the Runners
Cut the runner in half and use a few dimes in each miter slot to raise the runners. Apply Krazy Glue and press the board down for a couple of minutes before drilling countersunk holes to secure the runners.
Step 4: Create the Bridges
Next, you’ll need to make the front and back bridges. The back bridge should be clamped and countersunk with screws, ensuring it avoids the blade’s path.
Step 5: Cut the Kerf Line
With the back bridge in place, cut the kerf line but stop just short of the front edge. This will allow for smooth operation.
Step 6: Build the Fence
For the fence, cut a dado in a strip of plywood to hold the T-track. Use a router table or table saw for this step. Ensure the T-track sits below the surface for a clean fit.
Step 7: Attach the Front Bridge
Attach the front bridge with a screw and clamp the fence to it. Make sure the chamfered edge is facing the blade for dust management.
Step 8: Install the T-Track
Finish cutting the kerf line through the back fence and install the T-track pieces, leaving a gap for the blade.
Step 9: Create the Stop Block
Make a stop block to ride along the T-track. Use hardwood or leftover plywood for this. Drill a hole for the flange bolt and ensure it fits properly.
Step 10: Build the Miter Attachment
For the miter attachment, you’ll need two squares of different thicknesses. Cut them at a perfect 45 degrees and glue them together, ensuring alignment.
Step 11: Final Assembly
Once everything is assembled, you can lock the miter attachment into place using the T-track. This sled will now help you make accurate crosscuts and miters.
