Crosscut Sled

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Blog entry by Ken Dowswell posted 05-25-2015 08:12 PM 1250 reads 0 times favorited 2 comments Add to Favorites Watch

I have a 10” Rockwell Table Saw, which I bought many years ago, had it in storage when I lived overseas and finally this spring being semi rerired, put it back in service. I need a Crosscut Sled. Did a lot ot on-line research, found what I like and made it to suit my saw and me.

The saws main table is 24” wide and 22” deep, so I duplicated it using 1/2” birch plywood.

Runners are maple, trimmed to fit and glued to the bottom of the plywood.

Fence material is cut from using 1X6 select pine. Front fence is 1/2” higher than the highest cut provided with the 10” blade. Glued and screwed to the plywood base.

The rear fence is also 3/4” pine, doubled up, 1 1/2” by 5 1/2” and 30” in length. Attached to the front face is a 1/4” sheet Birch plywood. Here, what I did was to cut a 1/2” wide slot 3/8” deep, 1” from the top of the fence, to be used as a T slot. The plywood face is trimmed to allow the opening of a 1/4 or 5/16 T-bolt. I will make a stop block to be used with the T track. Along the bottom edge, I routed a 1/4” 45 degree cut, to prevent the accumulation of sawdust. No glue, only screwed from the bottom side of the base.

At the rear of the fence, I boxed in the center area to protect myself from contacting the saw blade. On both sides I placed uprights and inserted 3/4” dowelling to be used as handles, also to keep me away from the blade. Here for the four uprights I used pocket holes, no glue in case I need to take the rear fence off for any reason.

After completion and waxing the runners, they are nice and tight, slide well and will get better over time. After a number of cuts, checking with a square and a 5 cut method, I am pleased with the result.

-- Ken in Niagara Falls

2 comments so far

View ScottKaye's profile


773 posts in 2555 days

#1 posted 05-25-2015 09:52 PM

I really like those push bars you added. Haven’t seen those before. I need to incorporate those into my sled which at the moment is on the tight side since my maple runners have swollen with the humidity change.

-- "Nothing happens until you build it"

View Ken Dowswell's profile

Ken Dowswell

22 posts in 1716 days

#2 posted 05-26-2015 12:21 PM

What I learned from my on-line research was that the grain of the runners should run north and south (up and down) which will reduce the amount of swelling of the runners against the miter slot.

-- Ken in Niagara Falls

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