Crosscut sled for tablesaw

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Project by oscorner posted 06-12-2007 08:55 PM 10863 views 10 times favorited 16 comments Add to Favorites Watch

After my incident with the flying wood that I spoke to you about in my blog I decided to do two things to keep or minimize the possibility of it happening again. The first thing I did was to use LumberJocks’ woodworking store to purchase a foot switch, as was suggested by many of you. I got the Billy Pedal which is a dead-man switch(it must be depressed for the circuit to be made up. If you take your foot off of the switch the saw, router or lathe is turned off). Yes, I have used it on all three and it is great! I’d suggest that everyone get one.

Second, I built a crosscut sled for my SuperShop tablesaw. Not only does it guarantee my perfectly square cuts, but also gives me a way to clamp the wood so I don’t have to hold it. And with a stop block, no more chance of binding between the fence and saw blade. Of course, that was my fault because I didn’t put a block to reference off of, thus not leaving any room for the cutoff to not bind against the saw blade. I made the runner extend almost 16” ahead of the sled, so I could have the runners well engaged before the sled made contact with the saw blade and they extend 2” from the rear of the jig. The base is made from 1/8” hardboard and the fences are made from 2 X 6 ” pine. The fences were carpet taped sqare to the blade, then screwed into place. Afterwords, I double checked that the fences were still square to the blade. No glue was used.

-- Jesus is Lord!

16 comments so far

View WayneC's profile


14359 posts in 4898 days

#1 posted 06-12-2007 09:42 PM

Looks good. How big is the sled itself?

-- We must guard our enthusiasm as we would our life - James Krenov

View mot's profile


4927 posts in 4837 days

#2 posted 06-12-2007 09:58 PM

That sled will do the trick!

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

View Steffen's profile


326 posts in 4836 days

#3 posted 06-12-2007 10:07 PM

I also made a sled recently…frankly, I don’t know how I lived without one up to this point. I will post a photo of it some day. Nice sled here, thanks for the tip about the foot switch.

-- Steffen - Kirkland, WA

View Bob Babcock's profile

Bob Babcock

1809 posts in 4887 days

#4 posted 06-12-2007 10:49 PM

I like it Os. I need to do something myself. My sled right now is a 1×4 screwed to my mitre. I like how beefy you made it. One of the things I need to do soon is to make some improvements to my table saw. I can’t fit a bigger saw in my shop so I need to get creative (I also need to be able to carry it outside). Jigs like this will go a long way to make my small contractors saw perform at least reasonably well.

-- Bob

View Karson's profile


35224 posts in 5201 days

#5 posted 06-12-2007 11:35 PM

Os: I’d do one more safety modification. Build a little box on the front of the sled so that when the blade comes through, your fingers are not in the way.

Sometimes the out-of-sight blade makes you forget where it is going to show up. I seen them with clear plexiglass on the top so you can see how far the blade has come out, and stop the slide.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View oscorner's profile


4563 posts in 5112 days

#6 posted 06-13-2007 03:29 AM

Wayne, the sled is 16” X 48”. I just cut it 16” wide in my homemade panel saw and didn’t see a reason to cut it shorter.

Karson, I added the 2 X 4 piece on the back after I made the initial cut and marked it to know where the blade will be. I do intend on making two handles, one on each side, to hold onto so my hands are out of the blades path, but I may be able to incorporate a stop on the rear guides that will also aide in keeping me from cutting it in half by accident. Thanks for the idea!

Thank you, Mot, Steffen and Bob for checking it out.

-- Jesus is Lord!

View jockmike2's profile


10635 posts in 5047 days

#7 posted 06-13-2007 04:18 AM

Mark you are turning into a wood working fool. Even getting safe about it. Great job reminding all of us of safety first. jockmike

-- (You just have to please the man in the Mirror) Mike from Michigan -

View Obi's profile


2214 posts in 5038 days

#8 posted 06-13-2007 06:31 AM

not wide enough… but looks good. My first sled has been modified to enclude the t-track like Don's.

View fred's profile


256 posts in 4899 days

#9 posted 06-13-2007 05:03 PM

Good job Os. How is the 1/8” hardboard holding up? Glad you put something else at the exit to keep it safer.

-- Fred Childs, Pasadena, CA - - - Law of the Workshop: Any tool, when dropped, will roll to the least accessible corner.

View PanamaJack's profile


4483 posts in 4878 days

#10 posted 06-14-2007 06:10 AM

Cool sled Os,.

-- Carpe Lignum; Tornare Lignum (Seize the wood, to Turn the wood)

View oscorner's profile


4563 posts in 5112 days

#11 posted 06-15-2007 11:01 PM

Thanks, Obi. Fred, I though about a acrylic covered box like you have on yours, but chickened out and just put a board to protect me from the blade. I appreciate your words, jockmike…I’m affraid that I am getting carried away with woodworking. LOL.

-- Jesus is Lord!

View Obi's profile


2214 posts in 5038 days

#12 posted 06-15-2007 11:05 PM

that’s how it starts… you buy a tool, use the tool, buy more tools, and use them… Next thing you know, you have a shop full of tools.You become so addicted you think about making wooden spoons and forks. You try to think up ways to recycle your sawdust. You buy glue by the gallon and your only worries are is it going to be enough.

But then I don’t have to tell you that… you’re a Lumberjock

View oscorner's profile


4563 posts in 5112 days

#13 posted 06-15-2007 11:07 PM

Don’t forget wooden spatula’s, Obi! LOL. I’ve made one of those, too.

-- Jesus is Lord!

View scottb's profile


3648 posts in 5128 days

#14 posted 06-16-2007 12:12 AM

NIce sled… good idea about the foot pedal switch.

-- I am always doing what I cannot do yet, in order to learn how to do it. - Van Gogh -- --

View oscorner's profile


4563 posts in 5112 days

#15 posted 06-17-2007 01:01 PM

Thanks, scott…the LumberJocks gave me the foot pedal switch idea. What a great bunch of woodworkers!

-- Jesus is Lord!

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