Table Saw Crosscut Sled

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Project by bobasaurus posted 06-08-2014 06:23 PM 3645 views 4 times favorited 4 comments Add to Favorites Watch

After doing lots of awkward cuts with an old miter gauge, I finally decided to build a proper sled for my table saw. It’s made from 1/2” baltic birch ply, some kind of mystery wood laminated to make the front fence (maybe alder or cherry), maple on the back fence, and beech miter bars. I pretty much followed the wood whisperer video, with a few tweaks to match the size of my saw and setup of my shop. I added some t-track for a sliding stop block, and so far it’s working well. I used the 5-cut method to get this thing exactly square… I can take a 10” strip off the 5th cut and both sides are the same width to the thousandth of an inch. The only problem I’ve encountered is that small cuts seem to come out the slightest bit convex… might be from some slight wobble in the blade. I also made the curved hand placements a little off center by accident. I’ll tweak this someday, and maybe add a safety block where the blade exits the fence.

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

4 comments so far

View geekwoodworker's profile


378 posts in 2229 days

#1 posted 06-08-2014 07:59 PM

Looks good and I wish mine was within a thou in 10”. I think mine is 3 thou over 12” and I am happy with that. Not sure why the convex thing happens. Maybe your blade but ensure your mitre slots have a good fit (no wobble). Might move slightly when making that small cut. I have 3 of these. One for small, one for big and one for angles. Love them all.
Nice job.

View bobasaurus's profile


3633 posts in 3952 days

#2 posted 06-08-2014 08:13 PM

I just took a straightedge to the runners and noticed that they are a little curved on the sides. I may have to try correcting this somehow… maybe just some tape in the hollows. Guess I should have ordered some aluminum miter bars after all.

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

View Dan Hux's profile

Dan Hux

577 posts in 4143 days

#3 posted 06-09-2014 10:37 PM

Great looking sled,, I have a thin kurf blade that cuts everything with a convex type curve, I can change to a regular blade and it goes away. Doesn’t matter if I use my sled, the fence or push the wood past the blade with a mitre gauge

-- Dan Hux,,,,Raleigh, NC

View Carbide's profile


210 posts in 3214 days

#4 posted 06-11-2014 01:01 PM

Nice job. I used the Wood Whisperer plans to make mine too. I have never cut so square. It is within .001” in 24”.

-- When it feels like a job, it isn't a hobby anymore.

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