Cross Cut Sled #1: New, and far more accurate crosscut sled

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Blog entry by Jon3 posted 12-09-2007 02:18 AM 5841 reads 16 times favorited 5 comments Add to Favorites Watch
no previous part Part 1 of Cross Cut Sled series Part 2: Fences! »

NOTE All of my photos have been migrated to a new provider, and the links in my posts are likely out of date. You can find the photos here.

My old crosscut sled sucked. I made it before I acquired a lot of knowledge, but I’ve been dragging along with it for a while. I did some test cuts the other day, and realized just how out of shape it was, so I decided it was time for a new one.

So here comes the Cross Cut Sled Journey!

I decided I wanted a fence with a T groove on it, so I could fit in doodads and stop blocks and whatnot.
I have some fairly thick Ash leftovers, so I joint and plane it, then I taper the top to give it a little bit of style, and to get rid of a nasty chunk of wood. ;)

Then I drop a round over into the router table, and give the hand-side a more user friendly profile.

Then I route myself a little track in the other side for aforementioned doodads.

I chuck up my new Freud Ultimate Plywood blade, and grab a nice chunk of clean 13 layer BB Ply.

I slice off to ~4” chunks that I will glue and true up for the opposing fence.

I happen to have a stack of hard maple slides from the last time I made one of these, so I was up the table, and set some up in the grooves, riding on top of spacers (to lift them above table height to insure a good fit with the sled.

I drop the sled body so that the middle of the sled lines up with the saw blade, slide over my rip fence, and use a clamp with very light pressure to get the sled somewhat aligned.

Then I drop $1000 worth of weight on top of the sled, and let it dry overnight.

5 comments so far

View mrtrim's profile


1696 posts in 4929 days

#1 posted 12-09-2007 02:56 AM

i was looking at my sled the other day and thinking its time for a new one so thanks for posting. think ill build one quite like it nice job . i got everything i need except the 1000 $ weight . lol

View rpmurphy509's profile


288 posts in 4903 days

#2 posted 12-09-2007 03:23 AM

Wonderful weights, need some of those for my own shop (if the wife approves that is).

Off to read the other blogs in the series.

-- Still learning everything

View Thos. Angle's profile

Thos. Angle

4444 posts in 5011 days

#3 posted 12-09-2007 04:55 AM


-- Thos. Angle, Jordan Valley, Oregon

View BarryW's profile


1016 posts in 4955 days

#4 posted 04-08-2008 02:41 AM

Your posting gave me a good direction for a crosscut sled….thanks

-- /\/\/\ BarryW /\/\/\ Stay so busy you don't have time to die.

View GaryK's profile


10262 posts in 5037 days

#5 posted 04-08-2008 03:02 AM

Looks like a good start. Halfway there.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

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