Cross Cut Sled

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Project by MickeyD posted 09-08-2009 12:45 AM 9631 views 30 times favorited 20 comments Add to Favorites Watch

I have finally finished our cross cut sled. After a few false starts (Chinese plywood) and miss turns it is finished and cuts square. I thank Kelly Mehler for inspiration. Whenever I would feel frustrated or unsure I would watch his video and feel calm and confident again. Jed (Kindlingmaker) was ever patient and supportive….I think he just wanted the sled finished and usable. ; ) We bought a saw blade just for cutting plastic to make the safety cover and it worked well. The front fence was not quite square after sitting around so long, but a couple of passes through the drum sander fixed that. The base is 1/2” Baltic birch plywood and the fences are 5-4 red oak. The safety block is several pieces of red oak glued together. The sled is 20” x 34” and has a fence height of 4 1/2”. The plexiglass safety cover reduces the amount of sawdust being thrown into the air besides helping to hold down the wood and keeping my fingers away from the blade. The guard is made of 1/4” plexiglass and I dado cut the groves in the fences to hold it in place. Johnson’s paste floor wax was applied to the bottom for smooth sliding action. I am very happy with the project and I am looking forward to years of use. : )

-- -Willing to try

20 comments so far

View Innovator's profile


3589 posts in 4911 days

#1 posted 09-08-2009 12:48 AM

Congrats, Nice job

I really like the lexan saw guard.

-- Whether You Think You Can or You Think You Can't, YOU ARE RIGHT!!!

View Scott Bryan's profile

Scott Bryan

27248 posts in 5319 days

#2 posted 09-08-2009 12:56 AM

This is a nice sled, Mickey. I like the addition of the blade guard as well. I put one on mine because I have a bad habit of reaching inside the sled for the offcuts before the blade stops spinning. But I only put a shield in place and, you are right, it does throw off sawdust. I like the enclosed guard that you built not only for safety’s sake but also for controlling dust.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View cabinetmaster's profile


10872 posts in 5055 days

#3 posted 09-08-2009 01:03 AM

Nice job. Looks like the same size one I had at my cabinet shop. Cut many a cabinet part with it. Wish I had never parted with it or the saw.

-- Jerry--A man can never have enough tools or clamps

View BarryW's profile


1016 posts in 5404 days

#4 posted 09-08-2009 01:09 AM

that’s an excellent sled…and from the sounds of it is very smooth…and I like the guard…excellent.

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

View GrainTrain79's profile


20 posts in 4681 days

#5 posted 09-08-2009 01:39 AM


I recently built a sled and I love it. It makes cutting a joy. I find that it really helps to control the dust too.

-- West Seattle, WA

View GrainTrain79's profile


20 posts in 4681 days

#6 posted 09-08-2009 01:40 AM

what do you use for runners beneath? a piece of hardwood? or a piece of aluminum or brass? is there any play? One runner or two?

-- West Seattle, WA

View Matt Vredenburg's profile

Matt Vredenburg

193 posts in 4911 days

#7 posted 09-08-2009 03:39 AM

Congratulations on completing your cross cut sled. I know how projects can drag on and being able to say you completed something is a great feeling. I have build three cross cut sleds in my lifetime and each one gets better and better. Great job – i love the Plexiglas idea for safety.

-- Matt, Arizona

View MickeyD's profile


130 posts in 5024 days

#8 posted 09-08-2009 03:49 AM

GrainTrain79 I used 2 steel miter bars from Peachtree. They have spring plungers that can be adjusted to stop side to side play.


-- -Willing to try

View upperwoodsman's profile


40 posts in 4843 days

#9 posted 09-08-2009 05:34 AM

Hey I like the hole idea very useful Congrats
Nice Plexiglas idea

-- Scott JoBurg MI The More you know the less mistakes...........

View Big_Bob's profile


173 posts in 5206 days

#10 posted 09-08-2009 04:33 PM

Nice. I like the plexiglass safety cover. I may need to scrap mine out and make one like yours.

-- Bob Clark, Tool Collector and Sawdust Maker

View woodworm's profile


14477 posts in 5088 days

#11 posted 09-08-2009 08:27 PM

Nicely built sled.

-- masrol, kuala lumpur, MY.

View HarleySoftailDeuce's profile


320 posts in 4917 days

#12 posted 09-09-2009 06:52 PM

Very nice sled! Every time I come on this site, I add things to my to do list, and this is one of those items I really could use.

-- Paul, Bristol,Rhode Island

View panther's profile


59 posts in 4740 days

#13 posted 09-12-2009 03:54 AM

outstanding sled,very glad to see plexyglass shield cover the blade, the first time your fingers bump it instead of the spinning blade they will thank you

-- you must live for something or die for nothing (rambo)

View Woodlander's profile


9 posts in 4824 days

#14 posted 09-27-2009 04:15 AM

Wow – this is great!

I saw the one you based it on in a fine woodworking video – and yours is superb!

Great job!


-- "Government "help" to business is just as disastrous as government persecution... the only way a government can be of service to national prosperity is by keeping its hands off. " - Ayn Rand

View reggiek's profile


2240 posts in 4767 days

#15 posted 09-27-2009 04:43 AM

Cool Sled….one of the most useful jigs IMHO….that one is a keeper for sure…

-- Woodworking.....My small slice of heaven!

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