Introduction: Simple Crosscut Sled

In this video I make a cross cut sled using Kregs Precision Trak and Stop Kit.

This is a very simple afternoon build without the bells and whistles. The Kreg precision Trak adds a versitile stop block system that allows for fast repeatable cuts. The sled itself is made from a half a sheet of 3/4" plywood, so it is very affordable.

Materials

Tools

Check out the video for a full walk through.

Step 1: Cut List

Picture of Cut List

Break down your sheet goods into manageable lengths using your choice of a table saw (or circular saw. It is recommended to use a guide system with a circular saw. create your cut list to the designated dimensions.

Step 2: Back Fence

Picture of Back Fence

Pre drill and countersink one of the 20" x 4" piece of ply and glue and screw it to the other to create the back support for the sled

Step 3: Attaching Mitre Tracks

Picture of Attaching Mitre Tracks

lay your mitre tracks in your mitre slots on your table saw. Then align your fence to 20" so the blade is centered in the sled ( you can adjust this for your own preference if you would like, I chose the center because i wanted 20" to the left of the saw blade)

Step 4: Attaching Mitre Tracks Pt.2

Picture of Attaching Mitre Tracks Pt.2

Align the front of the sled base with the front of the mitre slot tracks. Screw the first one in using the proper length screws, and making sure to keep the base flush against your fence. After you fasten the first screw, slide the sled out and fasted the second, then flip the whole sled over for the final screw. This isn't particularly important it is perfect because you can adjust the fence later. Make sure the sled slides smoothly and adjust your tracks accordingly.

Step 5: Attaching Front Fence

Picture of Attaching Front Fence

Attaching the fence at this stage is simple. Counter sink a hole at each end of the base and fasten the 2 1/4" thick board to the back of the sled on each end. Do not over tighten, this pivot will be how you adjust your sled in the next step.

Step 6: Raising the Blade

Picture of Raising the Blade

Raise the blade slowly through the center of the sled making sure to keep your hands clear. Once the blade breaks the surface go ahead and slide the sled forward and back to give a reference of where the blade will be. DO NOT CUT THE WHOLE WAY THROUGH THE BASE OF THE SLED ON EITHER SIDE!!!!

Step 7: Attaching Back Fence

Picture of Attaching Back Fence

Attach the back support. Make it as square as possible, this piece isn't used for reference and is not 100% crucial to be perfectly square. So give it your best judgement, countersink and fasten using screws.

Step 8: Squaring the Sled

Picture of Squaring the Sled

Using the 5 cut method, square a piece of scrap wood on the saw as it stands. Make any adjustments needed to square the sled. Once adjusted , countersink and fasten down the fence. There is a link in the extras folder for the 5 cut squaring method in great detail

Step 9: Attaching Stop Track

Picture of Attaching Stop Track

Pre drill your precision track and attach it to the fence. You will need to cut 8" off of one of the track pieces to fit this 40" sled, this can be done on your mitre saw. The metal is soft and easily cuts.

Step 10: Front Support

Picture of Front Support

Add the support piece to the rear of the sled using countersunk screws. Avoid screws near where the blade intersects the fence.

Step 11: Blade Guard

Picture of Blade Guard

Countersink and attach the 6" x 2 1/2" piece of 2x4 where the blade exits the back of the sled.

Step 12: Waxing the Sled

Picture of Waxing the Sled

Wax the base of the sled with a paste wax and you're all done!

Thank you for watching and following along.

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Comments

Meglymoo87 (author)2016-05-19

I agree with Zencuke below...love the no frills 'ible! Great job :)

zencuke (author)2016-05-12

This is my favorite kind of Instructable. A clean basic design without frills with clear easy to follow instructions. But 8 minutes? It takes me longer than that just to do the 5 cut squaring. Heck it takes me 10 minutes to set up for a project like this, things like finding the glue and getting out all the tools. I'm an old guy and I take my time. This is about as clean and simple as a crosscut sled can be but if you can do the whole thing in 8 minute you are amazing.

John_Malecki (author)zencuke2016-05-18

hahaha well thank you very much. The title was actually a play on how long the video was. Shouldve been more descriptive, but its a bit late now. I am glad you enjoyed it though and hope you find some motivation to give it a try. It is simple and does not take very long at all

zencuke (author)John_Malecki2016-05-19

I'm on my third or fourth (at my age who can keep track?) but for some reason I made my current one a little small small and the end block is almost cut through. I've been meaning to make another but dread the squaring process. I'll let this Instructable inspire me to make it happen. ;-)

Jim Renderer (author)2016-05-11

I'm impressed. Very nice build & the Kregg stop rails are a nice addition.
I thimnk when I build mine I'm going to use my Kregg jig & pocket screw it together. What do think ?

pocket screws would work well if you want to take the time to make them. Would make for a good sturdy piece!

Jim65 (author)2016-05-11

Very nice and you did a great job explaining the process. Thanks for sharing.

John_Malecki (author)Jim652016-05-11

Thank you, im new to this platform and enjoy being thorough!

seamster (author)2016-05-10

This is a great looking sled. I like the addition of the built-in stops, which is something that's missing from the sled I'm currently using. I need to add those! :)

John_Malecki (author)seamster2016-05-10

its the whole reason i built it. Game changer over using a clamp and a block or something else. Its awesome having it built into the sled.

About This Instructable

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Bio: The Builder - 29 year old former NFL athlete turned full time Builder. Specializing in Industrial style Reclaimed furniture and Industrial design aesthetic.
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