Crosscut sled

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Project by TroutGuy posted 04-14-2010 07:48 AM 27678 views 92 times favorited 40 comments Add to Favorites Watch

This is one of those projects that I wish I had done sooner. I love my little Bosch table saw, but….it’s “native” crosscut capacity is about 7”, and that’s pretty limiting. So, after a bit of research, I came up with this. It’s a compilation of numerous designs from LJ and elsewhere. Best of all, it more than doubled my crosscutting capacity—~14” w/clamps or 16” without. Max thickness is ~2 3/8”.

The base is 3/4” MDF, with hard maple runners on the bottom. The fences are 2” x 3 1/2” poplar, and the guard is doubled up 3/4” plywood with a 1/4” acrylic cover. The flip stop is 3/4” HDPE from another project, and can be used on either side of the blade. I’ve got about $25 in the t-tracks, and the rest was ‘leftovers’.

As you can see in the last picture, I extended the guard far enough, that I can run the blade (at max hieght) completely through the cut, and it’s still completely covered.

It makes crosscutting 13” wide cutting board blanks a breeze.

As always, my SketchUp file is yours for the asking. Just PM me with an e-mail address to send it to.

Make one today. You won’t regret it!

-- There is nothing in the world more dangerous, than a woodworker who knows how to read a micrometer...

40 comments so far

View Robsshop's profile


923 posts in 4308 days

#1 posted 04-14-2010 10:00 AM

WOW !! that is the terminator of all sleds. Arnold would be proud. I too like the use of cross cut sleds,It makes things more safe and simple when cross cutting large or small pieces . Nice job!

-- Rob,Gaithersburg,MD,One mans trash is another mans wood shop treasure ! ;-)

View woodworm's profile


14477 posts in 4923 days

#2 posted 04-14-2010 10:31 AM

That is a cooool sled., nicely done!

-- masrol, kuala lumpur, MY.

View mafe's profile


13652 posts in 4422 days

#3 posted 04-14-2010 10:49 AM

The sled, to end all sleds – a Rols Roys.

-- MAD F, the fanatical rhykenologist and vintage architect.

View blockhead's profile


1475 posts in 4641 days

#4 posted 04-14-2010 11:42 AM

Now that’s a sled, great job!

-- Brad, Oregon- The things that come to those who wait, may be the things left by those who got there first.

View Dusty56's profile


11868 posts in 5021 days

#5 posted 04-14-2010 12:07 PM

Very nice construction : )

-- I'm absolutely positive that I couldn't be more uncertain!

View Maveric777's profile


2694 posts in 4409 days

#6 posted 04-14-2010 12:20 PM

Outstanding jig….

-- Dan ~ Texarkana, Tx.

View Chase's profile


448 posts in 4359 days

#7 posted 04-14-2010 12:30 PM

That is very fancy much! no need to make furniture or anything, your jig is work enough.

-- Every neighborhood has an eccentric neighbor. I wondered for years "who was ours?" Then I realized it was me.

View Porosky's profile


619 posts in 4697 days

#8 posted 04-14-2010 01:16 PM

Nice Sled It look dead on. You’ll need a second table saw for ripping.

-- There's many a slip betwixt a cup and a lip.--Scott

View Triumph1's profile


938 posts in 4412 days

#9 posted 04-14-2010 01:50 PM

Man I have been wanting to make one of these for years….I will have to bite the bullt soon. Greta job on this.

-- Jeff , Wisconsin Please...can I stay in the basement a little longer, please!

View Cozmo35's profile


2200 posts in 4369 days

#10 posted 04-14-2010 02:05 PM

Very nice design and final product! It looks like it’ll serve you well for a long time. If at all possible, I would love to see a copy of the sketchUp!

-- If you don't work, you don't eat!.....Garland, TX

View michelletwo's profile


2795 posts in 4348 days

#11 posted 04-14-2010 02:17 PM

golly, looks like it was built tank-tough. What does it weigh? I’m sure your crosscutting will improve greatly

View Mark Whitsitt's profile

Mark Whitsitt

86 posts in 4312 days

#12 posted 04-14-2010 03:04 PM

TroutGuy!! I’ve also got the Bosch Table Saw, and I desperately need to build a crosscut sled. I’d love to have your sketchup file/model! If you can share the model on the sketchup 3D warehouse and then post the shortcut to the page, I’d really appreciate it!!

Also, I’m curious about your rip fence add-ons! What do you have going on down there at the end of the table?? looks like you have an auxiliary fence, but I can’t tell what the part is that runs off perpendicular to the edge? Do you have a router platform down there?

Great sled!!! Thanks for sharing!


-- -- "there are many good reasons to use old hand tools, but moral superiority is NOT one of them..."

View Ken90712's profile


18099 posts in 4521 days

#13 posted 04-14-2010 03:35 PM

One of the best I have looked at on here Thx for sharing. Love the plexi glass.

-- Ken, "Everyday above ground is a good day!"

View BTKS's profile


1989 posts in 4797 days

#14 posted 04-14-2010 03:55 PM

I really like the rear blade guard. Keep up the good work, BTKS

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View chrisstef's profile


18140 posts in 4339 days

#15 posted 04-14-2010 04:53 PM

Seriously that sled is a beast … great work, and id love to take you up on the offer of the sketchup drawing

-- Its not a crack, its a casting imperfection.

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