New Table Saw Cross cut sled

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Project by Kevin posted 06-18-2012 06:50 PM 7979 views 12 times favorited 13 comments Add to Favorites Watch

Just finished it today. Most of the inspiration for it came from the wood whisperer’s panel sled. I looked at a few different designs, but Marks was just the most simple while still offering everything I was looking for. The dimensions of mine are 24 in deep x 48 in wide x 3/4 in thick. Made from birch plywood with hard Maple runners. I routed a 45 degree chamfer on all edges of the front and back fences. Checked it for square using the 5 cut test and to quote Mark it is close to “crazy good”. Thanks for looking.
Here's a link to the wood whisperer's cross cut sled.

-- Measure twice, cut once, then sand a whole bunch

13 comments so far

View Ryan's profile


38 posts in 2846 days

#1 posted 06-18-2012 08:50 PM

Looks good! I’m sure you’ll be using that a lot and it looks like it will work well for you. Good job!

-- If you want creative workers, give them enough time to play.

View Tokolosi's profile


678 posts in 2917 days

#2 posted 06-18-2012 09:33 PM

Great looking sled. Nice and wide! I need to make a new one soon. Dont you find that using the 3/4” base excessively diminishes your saw height ability? I generally make my sleds with 1/4” or 3/8” bases. But I could appreciate the extra stiffness.

-- “There is nothing like looking, if you want to find something. You certainly usually find something, if you look, but it is not always quite the something you were after.” ~ JRR Tolkien

View Scott Oldre's profile

Scott Oldre

1126 posts in 3993 days

#3 posted 06-19-2012 12:59 AM

I like the dimensions. Mine is only 18” deep and about 30” wide. My only concern would be the stablity/durability of using 3/4 for your rear fence. I used 2 pieces of 3/4 maple for the rear and added a 4” block where the blade would come through for a little extra safety. I’ve got to build a new one soon, as I’ve been lazy too many times and left the blade high while contacting the forward fence, so it’s a little floppy now. I think I used 1/2” ply for my base, which works well for me on my Craftsman table saw. I will say this, at least 50% of my cuts are using the sled. I have the incra miter sled, which I attach my Incra 1000SE miter gauge to, but use that mostly for miters of course. My original crosscut sled uses Oak runners, but the next one I think I’ll use some Incra miter sliders just for reliablity when going from summer and winter and removing the slop that comes with the changes. But seriously that’s a BIG SLED and you’re going to love repeatability it gives you in a nice 90 deg cut.


-- Scott, Irmo SC

View Alexandre's profile


1417 posts in 2753 days

#4 posted 06-19-2012 01:10 AM

Wow! THATS HUGE!!!!!
Why not put a blade guard?

-- My terrible signature...

View Kevin's profile


562 posts in 2861 days

#5 posted 06-19-2012 01:31 AM

Thanks Ryan, Tokolosi 1/2 in would have been my choice but I all that was in stock was 1/4 or 3/4 in hardwood. Since I needed 3/4 for a project anyway I used the left over for my sled, my only concern is the weight of this thing moving it on and off the saw. As far as cutting height I rarely need to cut anything over 3/4, occasionally I cut some 8/4 stock but the blade raise enogh for that. Scott, I actually was going to laminate 2 pieces of 3/4 birch ply together but didn’t have enough left. At first I thought it would be fine with just the 1 layer fence, but you got me thinking that over time with use and higher cuts it might be a problem. I’ll probably replace the fence with a laminated 1 1/2 in fence soon. I did orient the grain on my runners up and down to help with seasonal humidity changes, but it would be nice having aluminum sliders. Alexandre, I kind of put this thing together kind of quick for some panels I need to cut on a different project, The panels require close to the maximum cut I have on the sled the way it is. So I didn’t have much room for a blade gaurd in the back, unless I add one on sticking off the back. You gave me something to think about. Thanks everyone for your comments.

-- Measure twice, cut once, then sand a whole bunch

View thedude50's profile


3611 posts in 3040 days

#6 posted 06-19-2012 09:36 AM

i have to agree i dont thik the fence is thick enough I used 5 quarter walnut for my fence i am thinkin that may be to thin too

-- Please check out my new stores and

View Kevin's profile


562 posts in 2861 days

#7 posted 06-19-2012 01:52 PM

Thanks for the comments. Always nice to get other peoples perspective and ideas, thats how you improve.

-- Measure twice, cut once, then sand a whole bunch

View Ken90712's profile


17794 posts in 3751 days

#8 posted 06-19-2012 02:34 PM

Nice job, I made the same one only I doubled the plywood on the both fences and added a saftey block on the rear so if I do get stupid the blade won’t come out near me. I used the Woodwhispers plan and test cut and got here real close .00125 like he said thats crazy good.

Here is a post if interested. Agian nice work.

-- Ken, "Everyday above ground is a good day!"

View BigMig's profile


473 posts in 3175 days

#9 posted 06-19-2012 03:03 PM

Nice work, Kevin, and your timing is impeccable. I’m in the process of building one as well, and have been using the Wood Whisperer’s video as a guide. I expect that it’ll be far more usable (for me) than a miter gauge – even my Icra.

Have you found that you wish your runners were longer, or have you thought about other upgrades – like maybe a toggle mounted on the near fence (to hold stock) or lining the fence with a smooth laminate?

Thanks for posting this project.

-- Mike from Lansdowne, PA

View Kevin's profile


562 posts in 2861 days

#10 posted 06-19-2012 04:49 PM

Thanks Ken, I am going to add a safety block on the back cause its not hard to do and can make a difference if I do something dumb. Thanks for the link Ken I will take a look, I like comparing other designs to see what other options are out there. Mike, so far the runners are fine the length they are, I probably will add a toggle clamp in the future they are so nice. Lining the fence is a good idea. This has been way easier to use than my miter gauge for 90 degree cuts. Thanks for the comments everyone.

-- Measure twice, cut once, then sand a whole bunch

View kiefer's profile


5689 posts in 3229 days

#11 posted 06-24-2012 03:14 AM

All in all this will do a good job for you but the above comments are all valid points .
This is only the first sled you will be building ,they are just the most handy accessory for the table saw, the different versions can do many tasks safely and are a joy to use.
As to the safety block at the back consider to make it quite wide and it wll reinforce the back fence also .

-- Kiefer

View Kevin's profile


562 posts in 2861 days

#12 posted 06-25-2012 12:22 AM

Thanks kiefer, thats what I was thinking about too with the safety block kinda duel purpose, for safety and some extra reinforcement for the fence.

-- Measure twice, cut once, then sand a whole bunch

View thedude50's profile


3611 posts in 3040 days

#13 posted 06-25-2012 01:54 AM

did you check out William ing’s video it was key to the success I got on my sled

-- Please check out my new stores and

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