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Project by AJswoodshop posted 02-13-2013 12:23 AM 3782 views 5 times favorited 16 comments Add to Favorites Watch

There’s a lot of different ways you could make a sled like this, but I decided to keep it really simple and easy to build. The main purpose for having a table saw sled it to cut a perfect square cut every time. And it really handy for cutting wide pieces of wood too. And you can easily clamp a stop block to the back fence, or even the table saw fence can be used as a stop block for longer pieces.

Building materials,
A lot of people use 3/4” plywood for the base, the only problem is you lose 3/4” of blade height. A better way is to just use 1/2” birch plywood, because it’s just as sturdy and you can raise you blade up higher. For the runner use a hardwood like oak of maple and cut it to fit exactly in to your miter slot. Now don’t cut it exactly flush with the top, cut it a little shy. The reason for this is because if the is any sawdust in you miter slot, it going to raise the sled up a little above the surface of your table, this can lead to a cut that’s not square. For the front and back fences, I glued together three pieces of 1/2” birch plywood, the back fence doesn’t do anything, it’s just there for more support and looks. Since I’m not using the back fence for crosscuts, I just aligned it flush with the back edge of the base. Now the front fence must be square to the blade. Take your time doing this, you’ll be happy to know that your cuts are square. I also built a small blade box at the front of the sled so the blade doesn’t possibly touch my fingers. I made it out of more 1/2” plywood. I also cut a little chamfer on the front and back fence, so that the workpiece can go up against the fence without having dust stop it from making a square cut.

What can you do with a crosscut sled?

I find it really handy for cutting wide panels. And it has a longer fence which provides a lot more support than a miter gauge. And you can clamp stop blocks to the fence for reapetable cuts.

So build one! You’ll be glad you did!

16 comments so far

View Mark's profile


1079 posts in 3311 days

#1 posted 02-13-2013 12:26 AM

Very nice AJ. That’s on the to do list.

-- Mark

View AJswoodshop's profile


1057 posts in 3613 days

#2 posted 02-13-2013 12:40 AM


View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5389 days

#3 posted 02-13-2013 01:11 AM

Nice crosscut sled…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View AJswoodshop's profile


1057 posts in 3613 days

#4 posted 02-13-2013 01:45 AM


View BusterB's profile


2365 posts in 3345 days

#5 posted 02-13-2013 08:42 PM

Nice build AJ…..

-- Buster, Ocoee TN (Critics are men who watch a battle from a high place then come down and shoot the survivors - Hemingway)

View whitebeast88's profile


4128 posts in 3527 days

#6 posted 02-14-2013 12:13 AM

great sled aj.i know mine comes in handy.

-- Marty.Athens,AL

View df1k1's profile


19 posts in 3455 days

#7 posted 02-14-2013 12:36 AM

Looking to build one myself and wasn’t sure whether to use 1/2 or 3/4. Going with 1/2 now

View AJswoodshop's profile


1057 posts in 3613 days

#8 posted 02-14-2013 02:11 AM

Good idea! 1/2” is cheaper and works just as good!

View Jim Jakosh's profile

Jim Jakosh

27255 posts in 4442 days

#9 posted 02-14-2013 03:07 AM

Nice sled, AJ! they sure come in handy and work better than a little miter gage by having a bearing surface on both sides of the blade. I feel they make cross cutting safer, too!..................Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View docspencer's profile


453 posts in 3282 days

#10 posted 02-14-2013 03:54 AM

I’ve been thinking about making one of these but some plans are intimidating. This one looks great and fairly straightforward to build. Nice job!

View sedcokid's profile


2738 posts in 4935 days

#11 posted 02-14-2013 02:10 PM

AJ, I know that you will be getting a lot of use out of this great sled!! Nice Job too!!

-- Chuck Emery, Michigan,

View DIYaholic's profile


19921 posts in 4012 days

#12 posted 02-14-2013 02:28 PM

A great shop addition and well done at that!

You are welcome in my shop anytime…..
Anytime that is, you want to make a crosscut sled for my use!!!

-- 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 AJswoodshop's profile


1057 posts in 3613 days

#13 posted 02-14-2013 07:05 PM

Thanks guys!

View  woodshaver Tony C   's profile

woodshaver Tony C

8455 posts in 4690 days

#14 posted 02-16-2013 02:29 AM

Nice sled AJ! They sure do come in handy!

-- St Augustine FL, Experience is the sum of our mistakes!

View AJswoodshop's profile


1057 posts in 3613 days

#15 posted 02-16-2013 04:35 PM

Thanks Tony!

showing 1 through 15 of 16 comments

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