Super CrossCut sled

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Project by lanwater posted 12-22-2013 07:38 AM 6270 views 56 times favorited 28 comments Add to Favorites Watch

This sled is based on eagle lake woodworking cross cut sled. It has everything I wanted.
The following link has build details and how to videos
I have seen several sleds on LJ based on the original design.

I made a couple of changes to the original design:

1-I used 3/4 project grade plywood from Lowes instead of 1/2 called for in the design. I wanted something more beefy. Of course it is heavier.

2- I used plastic laminate on both sides. I wanted to have a more resistant surface. The plastic laminate slides better in my opinion. I also think it looks better. I can also write on it and erase it. I bought one sheet 4’x8’ from Lowes for $52. I have plenty left.

3- I changed the fence a bit especially in term of attachment. I did away with the track. The design I used allow me to have a stop much further from the fence without having a longer fence. I also don’t have to use flip stops.

4- I also shortened the moveable fences to my liking.

I have used this sled for a while and like it.

Fence build:

I cut a groove each half of the fence on the table saw using the regular blade in multiple passes. I did not feel like putting on a dado blade. I should have used a dado blade for a better groove.
glued those 2 halves together with a small piece of wood that fits in the groove at each end so that the 2 halves don’t move during clamping
once the glue dried, I used the jointer to get a face flat and one edge square. I the moved to the planer for the other 2 faces.
The final step was to cut a groove on the front face to act as a track for stops and accessories.

The base:

I scored the plastic laminate and bent it until it snapped.
I used a fence so I get it strait and to avoid tearing the sheet.

I applied contact cement to both the plywood an the plastic laminate. Waited until it became tacky then lay it into position with the help of dowels/rod.
I used the roller from one end to the other applying pressure and removing the dowels one at the time.
Once the dowels were all removed I rolled some more taking care not the crack the overhang edges with the roller.

I used a flush trim router bit with the palm router to flush cut the plastic laminated. I debated using a chamfer bit to ease the sharp edge or jus a sanding block. I opted for the sanding block. I think I will probably chamfer soon.

The moveable /miter fences:

I bought a 3/4 wide 1/8 thick and 8 feet long aluminum bar from Lowes and cut 4 pieces from it for the moveable fences. I cut those on the miter saw.
Drilled and countersink the screw holes on the drill press.
Cut the fences to length and the 45 degrees angles on the end on my Sawstop. I used the key to de-activate the brake system.

Ay suggestion to improve the design will be appreciated. Thanks for looking.

Merry Christmas to all.

-- Abbas, Castro Valley, CA

28 comments so far

View SPalm's profile


5338 posts in 5165 days

#1 posted 12-22-2013 01:43 PM

Wow, sweet.
My sled is just junk compared to this.

Good move with the laminate on both side. Slippery and it will keep the plywood flat over the years.

I like your T-bolt fence instructions. Looks easier than how I make them.


-- -- I'm no rocket surgeon

View ToddHolmDotCom's profile


99 posts in 4083 days

#2 posted 12-22-2013 01:48 PM

It looks like the perfect crosscut sled, one thing you could do to make it even better is send it to me. I’m just sayin’

-- Todd "I am just a teacher and a carpenter, that doesn't mean I have a God complex. But I am complex."

View Roger's profile


21055 posts in 4087 days

#3 posted 12-22-2013 01:59 PM

A very elaborate sled. Many uses. Very nice build.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View scarpenter002's profile


619 posts in 5188 days

#4 posted 12-22-2013 02:25 PM

Very nice addition to your shop. Thanks for sharing.

-- Scott in Texas

View mloy365's profile


448 posts in 4414 days

#5 posted 12-22-2013 02:37 PM


-- Mike - Northern Upper Michigan

View helluvawreck's profile


32122 posts in 4150 days

#6 posted 12-22-2013 02:44 PM

This is a great sled and will definitely be a wonderful addition to your shop.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View grumpy749's profile


228 posts in 3661 days

#7 posted 12-22-2013 02:59 PM

Wow, accurate miters or what. I love the attention to detail. nice tool.

-- Denis in Grande Prairie. Yesterday is history, tomorrow is a mistery, but today is a gift. That is why it is called the present.....Pink !

View Boris 's profile


190 posts in 4198 days

#8 posted 12-22-2013 03:12 PM

Very nice, you did a great job, congratulation .
Merry Christmas.

View Jerry's profile


221 posts in 4822 days

#9 posted 12-22-2013 03:50 PM

Excellent build!! I have a sled that works, but this is the upgrade I’ve been looking for.
thanks for sharing!!!

-- Jerry - Rochester, MN *Whether you think you can or you can't, you are probably right* - Henry Ford

View luv2learn's profile


3147 posts in 3586 days

#10 posted 12-22-2013 04:33 PM

This has been on my to do list for some time. Yours has inspired me to get er done. Great job.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View Diggerjacks's profile


2330 posts in 4422 days

#11 posted 12-22-2013 05:37 PM

Hello lanwater

Very great job

I have ever seen theses videos but I don’t have any time to make one like this.

I agree with you : with this crosscut sled we have all we needThanks a lot for the additionnal pictures and explications

Merry christmas

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Northwest29's profile


1713 posts in 3774 days

#12 posted 12-22-2013 07:16 PM

Great improvements and work -

-- Ron, "Curiosity is a terrible thing to waste."

View fernandoindia's profile


1081 posts in 4227 days

#13 posted 12-22-2013 07:21 PM

Hi Ian. That’s a jumbo super sled. I believe you only missed the blue toothed burglar alarm!
Cute fence building and aluminum bars. Love it.
Happy holidays

-- Back home. Fernando

View lanwater's profile


3113 posts in 4218 days

#14 posted 12-22-2013 08:48 PM

Thank you all for the niece comment.

Steve: there is no way I could match you t bolt track. Your are one of the best engineer on this site.

Fernando, you are going to laugh but I toy with 2 adjustable lasers, one in the front and one in the back, for special cuts. The one I have were too big. I am looking for smaller ones that I can embedded in the handle with a small cup so I can change the angle.

Last night I tumbled on a sled JustJoe made and it had a zero insert. I think that’s a great thing to have. It’s not too late…

-- Abbas, Castro Valley, CA

View hoss12992's profile


4180 posts in 3176 days

#15 posted 12-22-2013 09:15 PM

Wow, love the design that you came up with and all the attention to detail. Very cool. Awesome job

-- The Old Rednek Workshop

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