Safer table saw X cut sled

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Project by DonH posted 02-16-2012 01:56 PM 7085 views 27 times favorited 21 comments Add to Favorites Watch

I recently upgraded my table saw and decided to improve the safety of using it. I prefer to rip on my bandsaw when capacity allows so the table saw is primarilly for cross cuts.

I added a cross cut sled, outfeed table and overhead safety equipment storage (sort of in your face – no excuse not use the right gear).

The sled is fully enclosed and has dust collection through an overhead system using ABS plumbing parts. the travel of the sled is limited in both directions, back by the riving knife which I leave in place and forward by bench dogs in the outfeed table as shown. The blade is impossible to touch at any time – even the slots cut out of the clear plastic cover at the fence end (they are to accomodate stops) do not allow you to touch the blade even if you try. The blade is always contained within the sled structure.

Not a very big project but I thought it may be of some interest.

-- DonH Orleans Ontario

21 comments so far

View WVTODD's profile


120 posts in 3028 days

#1 posted 02-16-2012 02:26 PM

Nice design and i like the magical flotting organizer shelf.

View a1Jim's profile


117713 posts in 4060 days

#2 posted 02-16-2012 03:23 PM

Interesting sled.

View DIYaholic's profile


19848 posts in 3158 days

#3 posted 02-16-2012 04:33 PM

I love it. When a safety device becomes a non-PIA device, then it surely WILL get used. The “Adult Proof” Crosscut (wood not yourself) Safety Sled (APCSS)!! Even I may stay “finger full” & stitch free!

Thanks for sharing this!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View BTimmons's profile


2303 posts in 2968 days

#4 posted 02-16-2012 05:23 PM

I can see you put a lot of thought into this station. Well done.

-- Brian Timmons -



197 posts in 2818 days

#5 posted 02-16-2012 05:23 PM

WONDERFUL ingenuity, in making the use of table saw safe. I particularly like the clear plastic cover and duct collection system from the top of the cover. Thanks for sharing your project.


View Manitario's profile


2778 posts in 3366 days

#6 posted 02-16-2012 06:25 PM

That is a great idea. Any difficulty holding the workpiece with the plexi cover in place? As well, you appear to have a squirrel running down one of your teleposts in the “floating” shelf pic; does he clean up the shop after you leave?

-- Sometimes the creative process requires foul language. -- Charles Neil

View Grantman's profile


113 posts in 4509 days

#7 posted 02-16-2012 08:00 PM

Looks like you’re limiting yourself to maybe a 6” board. What happens if you have a panel, say, 15” wide?

View DonH's profile


495 posts in 3301 days

#8 posted 02-16-2012 08:13 PM

Hi all – thanks for the interest.

Manitario – the “squirrel” is my bench brush, sharp eyes!!

Grantman – the capacity is 9” crosscut and you are right, if larger panels need to be cut I would not be able to use this sled, but probably could use the bandsaw and rip the crosscut. Cant have everything in any one package it seems.


-- DonH Orleans Ontario

View Lee A. Jesberger's profile

Lee A. Jesberger

6866 posts in 4463 days

#9 posted 02-16-2012 08:24 PM

Very nicely done, Don.


-- by Lee A. Jesberger

View DonH's profile


495 posts in 3301 days

#10 posted 02-16-2012 11:45 PM

Hi Lee

Thanks – it was a fun project.


-- DonH Orleans Ontario

View StumpyNubs's profile


7730 posts in 3284 days

#11 posted 02-16-2012 11:50 PM

This is definitely going to the LJ’s top three! Thanks for posting!

-Jim; aka “Stumpy Nubs”
Blue Collar Woodworking? That's the best show since wood was invented! ”- The Eastern Northwest Southerner’s Journal

-- Subscribe to "Stumpy Nubs Woodworking Journal"- One of the crafts' most unique publications:

View DonH's profile


495 posts in 3301 days

#12 posted 02-16-2012 11:51 PM

Thank you Stumpy


-- DonH Orleans Ontario

View rmoore's profile


325 posts in 3118 days

#13 posted 02-17-2012 12:01 AM

Your design sucks… in a good way. I’ve never been a fan of the plastic cover but this serves a purpose other than keeping your fingers out of places you should know better to put them. Dust always blows out the slot in the back fence on my sled. This would help I’m sure. Favorited!

-- The more I learn, the more I realize I don't know. Ron, Crossville Tn

View DonH's profile


495 posts in 3301 days

#14 posted 02-17-2012 02:22 AM

Hi Rmoore

Thanks for your unique observation – dust sucks as far as I am concerned and sliced fingers even more so!!

The plastic cover does a good job.


-- DonH Orleans Ontario

View Vrtigo1's profile


434 posts in 3475 days

#15 posted 02-17-2012 02:43 AM

Just wondering how effective the overhead dust collection is. I wouldn’t expect it to be very good, so that’s why I am asking. Also, the overhead storage for safety devices is interesting, but I would worry about bumping into it and having something fall onto the saw in the middle of a cut. I think I am more inclined to make sure I am aware of what is going on and to think through what could go wrong with every cut before I make it when I am working at the TS, but to each his own. Thanks for posting.

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