Crosscut Sled

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Project by sras posted 09-22-2010 05:00 PM 73108 views 226 times favorited 64 comments Add to Favorites Watch

This crosscut sled was my second accessory I built for my table saw. I built this last summer from formica covered MDF and oak trim. I spent several hours searching the web for ideas that I wanted to include in my version. For some reason I never stumbled across Lumberjocks at that time. I saw a sled design on Woodsmith that is a starting point, but I made several improvements/changes. I have seen features here that I might add in the future. Let’s see if I can cover the details.

First is the size – it is 27” deep and 45” wide. This is as big as I felt I could handle. In the past year, there have been two times where friends have stopped by to use this sled because of its size.

I spent a lot of time getting the fence perfectly square. It took several clamped setups and test cuts before I was happy. Test cuts were done by squareing a wide board then flipping the board over and cutting a small piece off the end. The cutoff would show me twice the error of the fence. I would then cut four pieces and stack them to get a better estimate of the error.

The sled has two adjustable panels on each side of the blade. This way I can set the floor of the sled next to the blade even when I use a dado or tilted saw blade setup.

Cal asked for more information about the adjustable panels and runners. It seemed best to add that here rather than down in the comments. Each panel consists of the floor panel and a piece on each end. Each end is held in place with a bolt. That is a total of four bolts. You can see them in the first picture. There are total of 5 black knobs visible the lower right one is for an extension (described below). The remaining 4 knobs secure the adjustable panels. The first picture shows an end board fairly well – it is to the right of the blade guard (described in the next paragraph). The second picture shows another end piece well – on the back side and for the other adjustable panel. Hope that is clear ;)
The runners are hard maple. I used two of them. They were cut slightly (0.004”) large and fitted by sanding down.

End Edit

The box on the front of the sled completely covers the saw blade. This only works when used with my outfeed table . The stopped slots on the outfeed table stop the travel of the sled before it can pass through the blade cover (and then my hand). This is by far my favorite feature and one I highly recommend.

There are two adjustable miter fences – one right hand and one left hand. They rotate around a pivot point that is centered on the arc routed with a t-slot bit. Getting the pivot point and the arc concentric took some thinking but I figured it out!

There is an extension for cutting large panels. It locks into place with a single bolt.

Finally, there is a t-slot rail that runs the full length of the sled and the extension to let me lock down a stop block (which I have not yet built).

I find myself using this sled all the time.

-- Steve - Impatience is Expensive

64 comments so far

View jim C's profile

jim C

1472 posts in 4549 days

#1 posted 09-22-2010 05:15 PM

Beautiful and very functional.

View Daiku's profile


241 posts in 4358 days

#2 posted 09-22-2010 05:33 PM


Like you, I’ve been looking for the “right” sled to justify the time and effort in making one. I think you have come up with just the design. This is ingenious from the way you can adjust for dadoes to the miter gauge. How do the panels adjust for the dado blades and what type of runners did you use?

Thanks for posting,

-- Cal Noguchi

View Tomoose's profile


422 posts in 4824 days

#3 posted 09-22-2010 05:33 PM

Wow – that is a monster – love the design. Thanks for the post.

-- “I am always doing that which I cannot do, in order that I may learn how to do it.” Pablo Picasso

View Ken90712's profile


18113 posts in 4639 days

#4 posted 09-22-2010 05:50 PM

Man what a great looking sled. One of the best on here, well done.

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

View mafe's profile


13872 posts in 4540 days

#5 posted 09-22-2010 05:59 PM

Wauuuuu, thats one h… of a sled!
I would love to cruise up and down of wood alle on that thing.
Good thinking, and so beautifully made – love it!
Best thoughts,

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

View SplashMaster's profile


311 posts in 4311 days

#6 posted 09-22-2010 06:10 PM

great job very nice

View Kent Shepherd's profile

Kent Shepherd

2718 posts in 4737 days

#7 posted 09-22-2010 06:12 PM


Thank you for sharing


View Diggerjacks's profile


2331 posts in 4589 days

#8 posted 09-22-2010 07:00 PM

Waouh This is a beautiful piece

I love the design

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View zlatanv's profile


691 posts in 4685 days

#9 posted 09-22-2010 07:01 PM

Wow, that looks awesome. Nice work on all your jogs.

-- Z, Rockwall, TX

View Routerisstillmyname's profile


763 posts in 4959 days

#10 posted 09-22-2010 08:01 PM

Oh my, that’s not a Crosscut Sled, that’s lamborghini murcielago of sleds.

-- Router è ancora il mio nome.

View ScottnKY's profile


109 posts in 4514 days

#11 posted 09-22-2010 08:38 PM

You are not being honest. These are not Sleds and Jigs….That stuff is fine furniture !!!!

Awesome ….......I couldn’t use that. I would be afraid I would scratch it .

View McLeanVA's profile


493 posts in 4885 days

#12 posted 09-22-2010 08:47 PM

Good Lord that’s awesome!

I’m too hasty to get that detailed. Dovetails well with the reason why I still have to shim every board I cut on my homemade sled.

Nice work.

-- Measure, cut, curse, repeat.

View Chip's profile


1904 posts in 5543 days

#13 posted 09-22-2010 10:02 PM

Spectacular… Wow… What everyone else has said. I have a monster of a sled that I thought was great and this puts it to shame. Beautiful work Steve. Love it!

-- Better to say nothing and be thought the fool... then to speak and erase all doubt!

View BritBoxmaker's profile


4611 posts in 4487 days

#14 posted 09-22-2010 10:04 PM

What a beauty. Comprehensive too. Well done sir.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View RexMcKinnon's profile


2593 posts in 4646 days

#15 posted 09-22-2010 10:23 PM

Cool, love the arm for the angled cuts.

-- If all you have is a hammer, everything looks like a nail!

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