In Scott Walsh’s video titled “the FLAW with Ultimate crosscut sleds,” he addresses common issues with crosscut sleds and offers a solution that combines functionality with ease of use. Scott’s approach emphasizes creating a sled that is both lightweight and capable of handling larger cuts, making it an ideal choice for woodworkers.
Identifying the Problem
Scott begins by acknowledging the limitations of his current crosscut sleds. He states, “I have a problem this cross-cut sled is way too small and this cross-cut sled is way too heavy,” highlighting the need for a new sled that balances size and weight. His aim is to build a sled with a larger capacity while keeping it lightweight and user-friendly. To achieve this, he introduces a simplified version of the five-cut method, which he claims is easy enough for a third grader to understand.
Materials and Construction
Scott starts his project with a leftover sheet of three-quarter inch Baltic birch plywood, noting that while it’s not mandatory to use this material, it is essential to select high-quality plywood to ensure stability over time. He explains that he’s going to glue two fence pieces together to create a thicker and more stable fence. To ensure straightness, he clamps the pieces to a level, emphasizing the importance of accuracy in woodworking.
The Need for Lightweight Sleds
Scott expresses his dislike for heavy tools, admitting, “I am admittedly lazy and I don’t really care for lifting heavy things if I don’t have to.” This sentiment drives him to create a “small and mighty cross-cut sled” that he finds easier to use for quick cuts. However, he mentions that sometimes he still needs to make wider cuts, which leads him back to his older, heavier sled that he built six or seven years ago. Scott questions the common advice to build massive sleds, arguing that smaller, purpose-built sleds can be more practical in a compact shop.
Design Modifications
To enhance the sled’s usability, Scott decides to cut off a corner of the sled to reduce weight and improve stability. He explains that the workpiece will be better supported from the fence side and the front of the table saw. He considers drilling holes in the base to lighten it further but concludes that the sled will be light enough without excessive modifications.
Scott shares his frustration with wooden runners for miter bars, which tend to swell in humidity and shrink in dry conditions, causing inconsistencies. Instead, he opts for aluminum runners that can be adjusted with an Allen key, making them a more reliable choice. He emphasizes the convenience of having adjustment screws on top of the runners for easy access.
Assembly and Finishing Touches
As the assembly progresses, Scott highlights the inspiration behind his sled design, crediting Norm from the New Yankee Workshop for the panel-style sled concept. He notes that this design allows for a larger capacity while remaining lightweight. Before final assembly, Scott rounds over the edges to prevent injuries, sharing a tip on how to avoid frayed edges when working with plywood by using a climb cut.
Addressing Stability Concerns
Scott anticipates questions about the stability of the sled when mounted on the left side of the blade. He addresses this concern by explaining the mounting process for the miter bar, ensuring that the sled remains stable during cuts. He mentions using CA glue to secure the miter bar and employs a self-centering drill bit for attaching hardware, which simplifies the process.
Utilizing the Five-Cut Method
Moving on to the five-cut method, Scott explains its purpose and how he simplifies it for better understanding. He introduces the necessary tools, including calipers and feeler gauges, and walks through the process of measuring and adjusting the fence for perfect squareness. He emphasizes that the method is straightforward and does not require complicated calculations.
Final Adjustments and Features
After completing the five-cut method, Scott tests the accuracy of his adjustments, finding that the measurements are remarkably close. He secures the fence permanently and adds additional features to enhance the sled’s functionality, such as flip stops for consistent results. He mentions the importance of using quality flip stops, noting that he has found a reliable option from Veritas.
Conclusion
Scott wraps up the project by comparing the new panel sled to his older, heavier sled, highlighting the weight difference and ease of handling. He emphasizes that his design combines the capacity of larger sleds with the practicality of a lightweight option. For those interested in detailed plans for the sled, go here.
