Crosscut Sled

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Project by BarryW posted 04-27-2008 12:42 AM 3712 views 3 times favorited 7 comments Add to Favorites Watch

Yesterday, I did my first test runs cutting with my crosscut sled. It was off 1/32 over 10 inches. Not too accurate. In fact, disappointing. I thought that another board run through the jointer added with thumb screw micro-adjusters would be the trick. Let me think about that over night. Not a bad idea. Over night I realized I had 2 faces on my crosscut sled. If I turned it around…maybe the other side was square and would produce square results. That would mean I would have to change the router table/slotted section to the other side of the saw. (Yeah, a better saw with milled utility grooves would be the best…but no bucks.) So anyway, after dreaming and solving this problem all night, I went to garage and turned it around. First test…not great but promising. Maybe a better fence stop. Second test. And I threw my Starrett square on that block….well, for me it was accurate. Square…all four corners and across the faces and sides. Like it’s suppose to be. Problem solved. Third project down.

-- /\/\/\ BarryW /\/\/\ Stay so busy you don't have time to die.

7 comments so far

View brunob's profile


2277 posts in 5177 days

#1 posted 04-27-2008 12:46 AM

Glad it worked out for you. Those sleds, properly aligned, are great.

-- Bruce from Central New, if you'll pardon me, I have some sawdust to make.

View kenn's profile


813 posts in 4728 days

#2 posted 04-27-2008 01:08 AM

Good job, that sled is ready to be put to work.

-- Every cloud has a silver lining

View sandhill's profile


2128 posts in 4932 days

#3 posted 04-27-2008 06:20 AM

1/32” is close enough for me off the saw if thats the best I can get it. I am getting away from trying to get it perfect with a machine and now I use hand tools for a project after the machine cut and enjoy wood working much more since doing so. Most important though I have noticed a mark improvement in the quality and tolerance’s of my work since I made the change I also cut down the time I spend on set ups for machines. It turns out it does not take as long to build something and it comes out better with less stress.

View Scott Bryan's profile

Scott Bryan

27249 posts in 4830 days

#4 posted 04-27-2008 09:49 AM

Nice job, Barry.

You are ready to go to work now.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View unknownwoodworker's profile


221 posts in 4711 days

#5 posted 04-27-2008 04:39 PM

Next time anyone makes one of these, look into Incra Miter Sliders. They are made of metal so expand and contract. They are also adjustable after you install them. That way if there not square at first, you can adjust them.

-- ??? My mistakes heat the house. It's very warm in here. ???

View teenagewoodworker's profile


2727 posts in 4776 days

#6 posted 04-27-2008 06:58 PM

nice job Barry, its good that you were able to solve that problem. just like you did I always seem to solve problems in the night. (or realize the mistakes i made). Thanks for the post and great job!

View AaronK's profile


1512 posts in 4472 days

#7 posted 09-22-2010 12:03 AM

glad the solution was simple without having to modify anything. however, i believe making a pivoting fence is the best way to approach crosscut sleds, and it will allow easy “recalibration” if the thing ever gets bumped. the basic idea is that one end of the fence is fixed in place with a screw (but it can rotate a tiny bit). the other end is fixed either with a bolt and threaded insert, or a pan-head screw in a slightly oversized pilot hole, which allows you to make fine adjustments to the rotational angle of the fence and true things up pretty well and quickly/easily.

while i agree with sandhill that it’s best not to rely on machines for accuracy, it sure makes things easier if you dont have to work so hard to square things up on the shooting board – planing end grain is hard on blades :-)

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