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A couple cross cut sleds

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Project by sansoo22 posted 05-22-2021 01:52 AM 1224 views 4 times favorited 17 comments Add to Favorites Watch

This project started from wanting a bigger cross cut sled in hopes of replacing my GIANT Dewalt sliding miter saw with a much simpler miter saw. So I watched some videos, read some articles, and settled on a modified design from Bourbon Moth Woodworking.

Materials are baltic birch plywood, cheap Home Depot MDF, some T-track, and hold downs. Super simple but super handy to have around.

First two images are of my big sled. Its 30” wide with 18” on the left and 12” on the right. The inside depth is 17-1/4 so I gained 3” on what my big sliding miter saw can do and this sled is WAAAAY more accurate.

The second sled is a remake of my small sled that fits in a drawer. I only made it because I had enough pieces left over. I did not have quite enough MDF to do the fence and I wish I had. The fence is just ever so slightly crowned and had I used the MDF face I could have shimmed it.

One thing I didn’t see Bourbon Moth…seriously weird name…do with his design was add any sort of chamfer for saw dust. Since the fence sits behind the MDF bed I chamfered the MDF where it meets the fence. Its working out quite nicely. I used the big sled to make the small one and didnt get dust or chips interfering with cuts at all.

The forth image is of a material support runner I made from the last of the materials I had left over. It has a couple notches to accept 123 blocks. For long cuts set the fence an inch larger, drop in the block, and make your cut. It has a couple magnets that keep it firmly against the square tube of the rails.

And what good is a cross cut sled if they aren’t accurate? Well this is where that 1/2” MDF face came into play in those results. First up the small sled is averaging 0.003” to 0.005” out of square. So for wood working pretty much dead on as far as I’m concerned. However…

If you can’t read the image the caliper is reading 0.0005” out of square on the large sled. I seriously doubt that is accurate because that’s a Husky caliper and I’m not that good but i got the same measurement twice. I used the 5 cut method to get the results for both sleds and all I can figure is I used a machinists straight edge to shim the MDF on the large sled to make sure it was bang on.

The last thing I wanted to point out is my design leaves a bit of an ass on the sleds for a couple reasons. Most of the force you apply is on the fence and after time I assume that can effect accuracy. Also it makes a very nice SAFE place to put your hands.

That’s all for this one. As always I probably way over thought this project but I had fun and made something super useful.





17 comments so far

View TheDane's profile

TheDane

6007 posts in 4878 days


#1 posted 05-22-2021 02:28 AM

I don’t think you have over-thought these at all … as a matter of fact, I think you have done a superb job on both the design and execution!

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

View therealSteveN's profile

therealSteveN

8652 posts in 1789 days


#2 posted 05-22-2021 02:46 AM

Nice work X 2. I love the drawer sized sled. I would probably use it most. I believe you are correct about the push pull effect on the fence over time. If you can slow that down even a little it will be worth it.

I have seen the Bourbon Moth site a few times. I just assumed like a real moth is drawn to light, this guy is drawn to Bourbon. :-)

-- Think safe, be safe

View sansoo22's profile

sansoo22

1748 posts in 869 days


#3 posted 05-22-2021 02:55 AM

Gerry – I appreciate that very much. Execution is something I’ve really been focusing on. Slow down and do one step at a time.

Steven – I think you were the one that mentioned the force on the fence in another thread and helped guide my design choice. And yes the small sled gets used most. The drawback to the big sled is its heavy! I think it will be for batch creating parts…you DO NOT want to be lifting it on and off the saw a lot.

View Eric's profile

Eric

1806 posts in 1088 days


#4 posted 05-22-2021 10:40 AM

Great job, looks like it will do the trick. I need to add this one to favorites. Thanks for sharing.

-- Eric, building the dream

View controlfreak's profile

controlfreak

2739 posts in 816 days


#5 posted 05-22-2021 11:56 AM

I like the “Red Danger Zone”. Looks like a great sled.

View gdaveg's profile

gdaveg

319 posts in 417 days


#6 posted 05-22-2021 12:56 PM

Great looking sled. Having a fixture to make true 90 degree cuts is invaluable. I will look for Bourbon Moth WW on YouTube

I may make a new 90 degree sled for the AZ shop this coming year. Wife wants a new TV stand so that is next.

-- Dave, Vancouver, WA & Tucson, AZ

View pottz's profile

pottz

20130 posts in 2199 days


#7 posted 05-22-2021 07:25 PM

thats one of the nicest sleds ive seen here and there have been a lot.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View woodbutcherbynight's profile

woodbutcherbynight

10267 posts in 3624 days


#8 posted 05-22-2021 09:46 PM

Nice work, the red danger zone is a good eye catcher, highly recommend to anyone building one.

-- Live to tell the stories, they sound better that way.

View corelz125's profile

corelz125

3597 posts in 2191 days


#9 posted 05-23-2021 02:55 AM

Good idea for the place to push and pull. I’m always grabbing the fence. Thats the KatzMoses stop?

View sansoo22's profile

sansoo22

1748 posts in 869 days


#10 posted 05-23-2021 03:00 AM

Pottz – Thanks man. That means a lot.

Gunny – I think you gave me the idea to make the danger zone red. Something about human brains react to that color.

Corelz – Yep that’s the Katz Moses stop. I couldn’t find anything else I liked. I tried 2 Kreg stops and both seemed to suck. The Katz stop is a tad on the pricey side but it is rock solid and while i thought the micro adjustment feature was kind of lame I must admit its super handy and I’ve already used it quite a bit to dial in perfect length cuts.

View LeeRoyMan's profile

LeeRoyMan

2070 posts in 942 days


#11 posted 05-23-2021 03:19 AM

Nice sleds. I like the danger zone also. What did you use for tracks in the miter slot?

View sansoo22's profile

sansoo22

1748 posts in 869 days


#12 posted 05-23-2021 03:26 AM



Nice sleds. I like the danger zone also. What did you use for tracks in the miter slot?

- LeeRoyMan

I used a couple strips of UHMW plastic for the runners on both sleds. They fit snug but are still very slick in the slots. We will see how they wear over time. I don’t have a climate controlled shop so I wanted something other than wood runners. My last sled I used aluminum bars with little plastic adjustment screws and those were always wearing out and adding a little play to the sled.

View Peteybadboy's profile

Peteybadboy

3890 posts in 3164 days


#13 posted 05-23-2021 11:49 AM

Really nice sled. I have to look up Katz Moses stop

-- Petey

View Peteybadboy's profile

Peteybadboy

3890 posts in 3164 days


#14 posted 05-23-2021 11:58 AM

Katz Moses stop- I can see plenty of videos, but no way to buy one?

-- Petey

View TheDane's profile

TheDane

6007 posts in 4878 days


#15 posted 05-23-2021 01:57 PM

Katz Moses stop- I can see plenty of videos, but no way to buy one?

- Peteybadboy

Try the Jonathan Katz Moses website.

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

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