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

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.