CrossCut Sled with Extension + outfeed table for contractor saw

Built this CrossCut sled using 3/4” Plywood. Fences are double layer 3/4” Plywood.

I used the kreg miter rails and top track.

I created an extension for the fence using a 1/2” aluminum rod and screws to attach the extension.

Using the 5 cut method, I lucked out and had a difference of only .0005” over 7” long 5th cut.
I couldn’t believe it and duplicated the .0005” difference! I was completely amazed.

The sled works great. I did have to extend the flip stop since it was designed for a shorter fence.

It was a bit heavy at the end of a cut, so I built a quick outfeed table that slip fits into the frame of the saw.

I also embedded a magnet inside the fence and created a 1” block with magnet that can be used as a stop block and the table saw fence/rule. I just have to add an inch. since the block is small, there is no pinch hazard, as the end of the piece is off the stop block before it can pinch the blade.

AJ