Cross Cut Sled

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Project by Phil B. posted 02-17-2019 12:58 PM 1330 views 6 times favorited 8 comments Add to Favorites Watch

The webbed extensions on my old Craftsman Contractors saw has always caught the edges of thin stock or laminate… I have added panels to both sides so my taper sleds slide between them. A wing nut and wood block hold them in place in the webbing.

So I have now finished the fence for my crosscut sled. As you can see it gives me great flexibility with long, large, or small parts. I added a safety stop to the end of my outfeed table, to avoid the danger of leaning way over to see if the cut was finished. The stop is adjustable to the depth of the blade, and also stops the blade from cutting the fence in half.

Since the sleds are square to the blade as well as square at the front end, I added a lip to the fence that butts against the sleds when they are pushed to the stop, so it auto squares. I very quickly double check with a square, tighten the track knobs, then insert bolts through the sleds from below to attach and tighten the handles….they are offset to the track knobs so they counteract any chance of twisting. I did the 5 step cut to check, and it was perfect.

The stop blocks on the center part of the fence are slotted to force pressure on long stock like the 2×10 shown, which prevents the cut portion from flipping off the table. The other stops allow for longer cuts up to 24” as shown. The extension fence has a slot allowing a 48” cut. Measuring is a breeze as the tape fits into the blade slot.

I have 37”x14” panels as well as rails and stiles for kitchen cabinets to make, so this sled will get a lot of use.
Tapers are now safer as the cutoff stock doesn’t drop off the sled, and I can angle cut larger sheets with ease. I posted a video on Instagram of my new Adirondack Bar Chair prototype. The second video shows the taper jig in action on back slats and the long legs.

I have seen some pretty big crosscut sleds out there, and I haven’t got that kind of storage space for a large sled…..ALL of these parts quickly come off the saw and stack on each other under the new outfeed table that I keep in the parallel position now at all times. When all parts are cut, it also gives me an additional level assembly area.

I will be posting the new chair soon, when I make the final parts this week. Thanks for looking.


-- Phil, DWG files at

8 comments so far

View therealSteveN's profile


2371 posts in 904 days

#1 posted 02-17-2019 08:40 PM

Even with a solid top a side platform keeps the offcuts up, and allows for a smoother parting of pieces, no more “hanging chad” at that very last piece hanging on tries to part off, but often breaks.

It’s why a sled can offer such clean cuts, and also why Rockler sells their little sled with an offcut board available.

It’s great when a jig, or fixture makes your work better, while offering a much higher degree of safety. Win win.

Thanks for posting.

-- Think safe, be safe

View Phil B.'s profile

Phil B.

178 posts in 1584 days

#2 posted 02-18-2019 01:55 PM

Thanks Steve. This complete package has been a game changer in my little shop. The time I have spent in the last 2 months making jigs for each tool has made a huge difference in safety as well as accuracy and productivity.

-- Phil, DWG files at

View Dreggy's profile


95 posts in 1935 days

#3 posted 02-18-2019 02:13 PM

Beautiful sled! Funny thing is, sometimes I appreciate a sled, jig, etc. I have to build to do a project as much as I do the finished project. :)

-- No matter how many mistakes you make or how slow your progress, you're still way ahead of everyone who isn't trying.

View Phil B.'s profile

Phil B.

178 posts in 1584 days

#4 posted 02-18-2019 11:59 PM

Thanks Dreggy…. I just found out today, while cutting back slats for my new bar chair, that I can joint the rough edge of a board with the right hand sled, while the taper jig is still attached to the left hand sled. :)

-- Phil, DWG files at

View bushmaster's profile


3598 posts in 2612 days

#5 posted 02-19-2019 03:01 PM

That is really nice. Great engineering.

-- Brian - Hazelton, British Columbia

View Phil B.'s profile

Phil B.

178 posts in 1584 days

#6 posted 02-19-2019 07:06 PM

View dannmarks's profile


865 posts in 911 days

#7 posted 02-28-2019 12:05 PM

Saved as a favorite – I like it…

View Phil B.'s profile

Phil B.

178 posts in 1584 days

#8 posted 03-10-2019 02:13 AM

Saved as a favorite – I like it…

- dannmarks

Thanks…easy to build and great to use

-- Phil, DWG files at

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