Crosscut Sled and Push Stick

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Project by patcollins posted 01-22-2011 11:56 PM 3521 views 0 times favorited 4 comments Add to Favorites Watch

I made myself a crosscut sled using Luan Plywood and some Pine for the fence. I laminated two nice pieces of pine together with the grain going the opposite directions (you can see in 2nd picture). I used some T-Nuts on the bottom of the plywood and bolts going through the fence thinking it would allow me to adjust the squareness if it ever came out of square, but…. that turned out to not be all that strong and the luan isn’t the strongest plywod and started to crush under the T-Nuts so I decided to square it up nice and glue it in addition to the bolts. I am a little disappointed with this because I went all out and got expensive stainless steel bolts and T-Nuts but thats ok. The runners on the bottom started out as square 3/4” hardwood dowels, I sliced them down the middle with my bandsaw and then planed them down smooth. In the end I have a sled that cuts very square, looks alright and didnt cost very much.

The pushstick is made out of 1/2” thick piece of red oak, I cut it out on my little 9” Skil bandsaw and finished it with Minwax wipe on satin poly.

The green things in the picture are a pool noodle that i sliced and slide over my fence rail to protect my car door from being dented if it hit it.

4 comments so far

View Paul Pomerleau's profile

Paul Pomerleau

309 posts in 3905 days

#1 posted 01-23-2011 01:18 AM

Very nice, I like it.
I’m just getting into woodworking myself since Christmas and a crosscut sled is one of my high priority projects.
I wanted to do what you tried, using bolts to fine tune the fence if needed.
I have 1/2” russian birch plywood for the base, the type with many thin layers, do you think that would work?
I like your push stick too, another project that I have to do.
Keep up the good work.

-- Close to Ottawa Ontario Canada

View patcollins's profile


1687 posts in 4077 days

#2 posted 01-23-2011 01:28 AM

The Russian Birch is much stronger so I wouldnt see why not, I think 3/4” would be better though. Word of advise it is really hard to get both holes exact on both the plywood and the fence, I was certian mine would be dead on straight but they weren’t. Fortunately there was enough play it didnt matter.

View Dusty56's profile


11863 posts in 4900 days

#3 posted 01-23-2011 02:59 AM

Nice sled , Pat : )

pauljp , The 1/2” Russian Birch ply is more than enough for the base especially if you use a full width fence .
I made my sled with front and rear full width fences and used 3/8” ply for the base. No problems : )

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

View richardc's profile


2 posts in 3827 days

#4 posted 02-03-2012 05:47 AM

This looks very nice. Having used a similar sled for over 20 years, one thing I might suggest as a safety feature is that you add a block of wood at the front (where the saw kerf peeks out) to bury the saw blade.

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