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:

Materials:

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

Wood screws

Wood glue

Tools:

Drill and bits

Table saw

Screw driver

Step 1: Materials

Picture of Materials

To make it - there’s no need much. A base, two runners and two supports at sled ends.

Step 2: Runners

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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.

Comments

HardyN (author)2017-11-02

Still like my old radial arm saw best for crosscutting and save to.

jgoldsack (author)2017-10-31

One suggestion I would make, more for safety than anything else, is to add a extra block or a box to cover the spot where the blade exits the front fence, to protect ones fingers.

Otherwise, nice and simple!

the norm (author)jgoldsack2017-11-01

I was going to write this also. I was just looking to see if it had been said already.

AlphaOmega1 (author)2017-10-31

Nice and clear, simple and efficient

May I suggest a simple modification for safety? Add a block at the rear of the sled so that the exiting blade is covered.

The five cut method you mention can make a huge difference. well worth the effort. Anyone making a sled should check this out.

Rue Shamrock made it! (author)2017-10-31

Good build and the essentials for a cross cut sled!

I own a DW7480, same as your saw with just a wider rip fence. My cross cut sled is based on a 24” x 24”, 1/2”plywood I bought from local Home Depot with three additional features: 1) taller fence to allow maximum saw height without splitting the sled; 2) extra Center block (painted red) to cover the spot where the blade exits; 3) stop blocks to prevent the blade going pass the end of the Center block. The stop blocks are added to the bottom left side of the sled (since my sled base overhangs the table/bench) and second block screwed on to the left side of the saw below the bench but just on the far side of the lifting handle slot yellow plastic. A few screws need to be disassembled to allow the yellow plastic piece to be pulled out enough to screw the block from the inside near the top. By adjusting the length of these two blocks (the one below the sled is easier), the sled stop distance/range can be established.

I wish I had see your instructions before building mine... Clean and simple with 5 cut method to check for squareness of the sled fence.

I have attached two picture of my cross cut sled in case others who own the same compact DeWalt job site saw want to build one. Cheers!

dgduino (author)2017-10-31

I'm a happy owner of this table saw, and you give me a great idea, Thank you !

PatN6 (author)2017-10-31

I have been meaning to make a crosscut sled for some time. Seeing what you've done and all of the photos makes me confident enough to do it now. Thanks.

rsucgang (author)2017-10-31

We have the same table saw and I've been meaning to make a sled. thanks for this instructable.

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