Introduction: How to Make a CrossCut Sled for Table Saw
This time I’ll show you how to make a simple and accurate crosscut sled for my job site table saw.
How I did it - you can check by looking DIY video or you can follow up instructions bellow.
For this project you will need:
50x50cm 1cm thickness plywood or other sheet of material for sled base
Two wood pieces for runners
Two wood pieces for sled front and back fences
Drill and bits
Step 1: Materials
To make it - there’s no need much. A base, two runners and two supports at sled ends.
Step 2: Runners
Runners was cut exact size to fit snugly to miter slots. They must be recessed a little bit below of surface of the table. I put few washers underneath runners just to raise them above the surface of the table.
Step 3: Sled Base
Add some wood glue and put plywood piece on top. I used table saw fence to square everything up, but at this point that’s not necessary. We will adjust squares later.
Put some weight and left for an hour.
Step 4: Securing Runners to the Sled
When glue was dry enough, pre drilled, counter sinked and screwed runners with wood screws.
Step 5: Sled Back Fence
Now time for front and back fences. First attached back fence. It doesn't have to be square, because the only function what it does - is to hold sled together after cut in center will be made.
Step 6: Front Sled Fence
Starting attaching front fence by screwing one wood screw in one corner and second in opposite side. Because my plywood base was perfectly square - I aligned front fence with base edge.
After that checked squareness. I’m measuring squareness regarding fence, because fence is parallel to table saw blade. And all looks pretty good.
Step 7: In Progress
Now slowly raised table saw blade and made a full cut along the sled.
One more time - squareness check, and it looks good.
Step 8: 5 Cut Method
Time for more precise squareness check called 5 cuts method. You could easily find tutorials and explanation on youtube about it. I was using this video tutorial to make needed adjustments click a clink.
Regarding my caliper readings I got 0.9cm at one end and 0.89cm at other. So I’m really close. Made needed adjustments to get perfect cut, pre drilled and screwed front fence to final place.
Step 9: Result
And that’s it, most my usable table saw jig is done. I hope this will help you to build it by your self.