How to Make a Simple Crosscut Jig

by diycreators

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Intro: How to Make a Simple Crosscut Jig

In most shops, space is a premium. As a DIY-er with multiple interests, everything needs to be stored somewhere. I needed a crosscut sled that I can take anywhere and then store it when it's not in use. I also used the miter gauge that came with the table saw as one of the miter bars. So this is my solution. Feel free to improve what you may find more useful to you.

Build Time: 3 hours

Difficulty: Easy

Item used:

Plywood
Scrapwood
Self-centering bits/ Hinges
T- Track Kit
Fence Flip Stop
Adhesive tape
Plastic spacers
Plexiglas
Small hinge
Digital caliper
 Hex-head threaded nut

(2) 3-inch screws For the blade cover
(2) 2-inch screws For the Miter gauge

For more details check out the plans here https://gum.co/PUYL

STEP 1: Making the Fence

I used two 3-inch plywood sandwiched together (glued). Next, I ripped the plywood on the table saw to create a straight edge. The height can be as tall as you like -- all personal preference.

STEP 2: Making the Miter Bar

To make the miter bar, I am going to use a digital caliper. This will help me measure and set the spacing for the table-saw blade from the fence. Carefully, rip the piece of wood using a push stick, and be sure to keep your hands and fingers out the way.

Next, cut a piece of wood for the rear support. Since the miter gauge is on one side occupying that slot, this will be for the other miter slot. Keep in mind you can make the back support whatever size that seems to be comfortable with you. I made mine compact. Cut the wooden miter bar down; this way it's not extended past the fence.

STEP 3: Attaching the Miter Bar

Clamp the miter gauge to the fence. Dill and install the threaded insert (this allow you to attach and detach the miter gauge) without running the wood. Make sure you square up the fence to the framing square. Glue and attach the wooden miter bar. Be meticulous to get this as accurate as possible.

STEP 4: Installing the T-Track

This T-Track is optional, but I think it's handy to have (great for the Fence Flip Stop). The available space on top can be for the Adhesive measuring tape.

STEP 5: The Blade Guard and the Dust Guard

At this point, the sled is nearly ready to go. Turn on the table saw and make your first cut, go all the way through. Then attach a piece of wood on the back side (closest to you). This wood can be as large as you like.

Note: The saw blade should never exit this piece. If you ever cut through this piece of wood, replace it!

Next, add a piece of plexiglass on hinges as shown in the photos. This will prevent the sawdust from flying toward your face. You can permanently attach, or make it removable as I did.

STEP 6: Test

Here are a few test cuts I made if you are new to woodworking and need to get an idea of how this works.

About this jig.

- Make safe cut crosscuts on a table saw

- Repeatable cuts

- Made Dados

- Small footprint

- Use your existing miter gauge

- Hinged dust guard

If you find this helpful be sure to stop by my youtube channel and subscribe for more home and shop projects.

21 Comments

Hal4884 6 years ago

I am going to make one similar to this. skipping the instrucable cause this one pretty much covered it. I anticipate some excess material that I am considering using for a jig toward my small drill press. I may look at instructable on that but . . . we'll see.

PeterD9 6 years ago

Well done! I have just made a variation of your 'Sledge' or more accurately a 'cross-cut fence'. Easy to make, easy to use, easy to store. My main change was the 'flip fence stop' I used a bracket from Toolstation (www.toolstation.com/shop/p88994?table=no) Great idea thanks for the post.

storm_child_277 6 years ago

Thanks, Very Compact and straight forward jig. I think I'll build this and place an eye bolt in one end so it can hang on my tool wall.

roylg 6 years ago

Very nice job. Great video full of good tips and clear explanations.

TBuck32 6 years ago

I am glad I have not made a sled yet... I think this is the best I have seen and I intend to make it. Thank you

HollyMann 6 years ago

You did an amazing job here. It looks a bit complicated, but I need one of these. I hope to come back to this and follow the instructions in the near future. I will favorite this and subscribe to your youtube channel. Amazing work!

diycreators 6 years ago

Thank you, I seen your work I'm sure you can do it :)

mrdawson 6 years ago

Beautiful Instructable. Thank you!

mevans12 6 years ago

Nice build, I appreciate your sharing.

CPUDOCTHE1. 6 years ago

Cool I made one of those LONG before Al Gore even invented the internets. I mostly used it to cut cabinet doors when I built my house.

autotech1 6 years ago

I made the rip fence for my home made table saw based on your design because it was the best option for my needs: https://www.youtube.com/watch?v=y0R5rO1jJqM&t=10s
When I build a crosscut sled I'll probably base it
on your design too because it's designed to get the job done efficiently while taking up minimal space. I'll need to figure out a way
to attach it to my miter gauge because mine doesn't have any holes to
mount the sled and I don't necessarily want to drill into it either. I
might just buy another miter gauge to use primarily with the crosscut sled. That depends on the cost of the miter gauge though.

HollyMann 6 years ago

One more comment here...I Just checked out your Youtube and WOW! You are incredible. I saw the desk build with the hidden compartment - stunning and love your style so much. I'm in awe. I know it's time consuming to post on here too - but I hope you keep posting on Instructables and sharing your projects.

acheide 6 years ago

Nicely done. Thanks.

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