Small XCut Sled

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Forum topic by Roger posted 07-23-2016 08:09 PM 1671 views 4 times favorited 21 replies Add to Favorites Watch
View Roger's profile


21055 posts in 4138 days

07-23-2016 08:09 PM

Topic tags/keywords: crosscut sled

Between all my distractions, I have managed to make a mini xcut sled. I’m hoping to make some small jewelry, and keepsake boxes here in the future. Made with 1/2” Baltic Birch ply, and 1/4” hardboard for the blade insert for straight cuts and angle cuts. The miter tracks are from a plastic/phenolic cutting board that can be found at Walmarts, Meijer, etc., even some Harbor Freights: here: Hope the pics tell the story:

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

21 replies so far

View Ivan's profile


17136 posts in 4202 days

#1 posted 07-23-2016 08:38 PM

Awesome idea to have same jig for different cuts. Excellent.

-- Ivan, Croatia, Wooddicted

View Redoak49's profile


5466 posts in 3323 days

#2 posted 07-23-2016 08:47 PM

Very nice and I like and use a smaller sled…good ideas.

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5386 days

#3 posted 07-23-2016 08:50 PM

Super Simple Cross Cut sled!

What are the dimensions, just to be clear…?

What did you use for the runners & where did you get them?

That box showing your Miter cuts is cool too… (size?).. Looks huge in the picture…

Great sled!

Thank you very much!

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

View Jim Jakosh's profile

Jim Jakosh

27243 posts in 4439 days

#4 posted 07-23-2016 09:05 PM

That is a great little sled!! A small sled is nicer to handle for little parts.

Cheers, Jim

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

View Roger's profile


21055 posts in 4138 days

#5 posted 07-23-2016 09:10 PM

thnx guys.
Joe: It can be made with any dimensions, but this one is about 13 1/4” id, and 31” long. The front and back fence are about 2” tall. The big block where the blade comes through is just laminated plywood scraps and I attached it to the fence above the “1/4” hardboard insert/s. I have an insert for straight cuts, and one for 45degree cuts. Brass screws hold the inserts in place. The sliders are just from those plastic/phenolic cutting boards that you can buy at Walmart, Meijer, or even Harbor Freight has them…. here @ HF: I am really happy that the 45 degree angle on the saw is right on. The “test” box is just a scrap piece of 3/4” ply that’s about 5” high, 11”long, and 6” wide. I wanted to be sure the angle cuts were going to be good, and they are. Thank you Grizzly. LOL…......although, it wouldn’t take much to dial it in.

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

View lew's profile


13488 posts in 5089 days

#6 posted 07-23-2016 09:42 PM

I like the angle cutting options/inserts. Wish I would have done that on mine.

Everyone knows how frugal (spelled cheap) I am. I get my cutting board plastic from a local restaurant when they throw out their stained boards. The make great gluing surfaces, too.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View andy_P's profile


433 posts in 4542 days

#7 posted 07-23-2016 10:38 PM

Great looking sled, Roger. I use one myself, so I understand how handy they are. Of course yours looks like a work of art compared to mine. I like that idea of using the cutting board material instead of hardwood I used.

-- Wood is a gift from God/Nature that maintains its beauty forever via the hand of a woodworker.

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5386 days

#8 posted 07-23-2016 10:47 PM


I have some of those white cutting boards… that we do not use anymore…

NOW, I have to find’em and put them to good use…
... I forgot ALL ABOUT using them for this use!!

Thank you!!

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

View doubleDD's profile


10918 posts in 3377 days

#9 posted 07-24-2016 12:02 AM

I like the smaller cutting sled a lot. Will have to make one. We have an old green cutting board I ca confiscate.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Grumpy's profile


26812 posts in 5185 days

#10 posted 07-24-2016 12:18 AM

Nice one.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View runswithscissors's profile


3134 posts in 3359 days

#11 posted 07-24-2016 12:55 AM

Phenolic is a much different plastic (same stuff as Formica) than polyethylene or polypropylene. They are softer and more easily deformed. I mention this because I tried using some HDPE for runners on an X-Y table for my mortiser, and had trouble with the plastic deforming when the flat head machine screws were tightened. Had to go another direction altogether.

-- I admit to being an adrenaline junky; fortunately, I'm very easily frightened

View kiefer's profile


5852 posts in 4001 days

#12 posted 07-24-2016 04:34 AM

That should work just fine but you could save some setup time by making sliding panels which will make it easier to adjust for different blade width , even a dado head and different blade tilt angles .
I have made a couple sleds with sliding panels now and they work great and are very simple to build .
Here is a video demo link to my sled if you like to take a look .


-- Kiefer

View CFrye's profile


11407 posts in 3174 days

#13 posted 07-24-2016 02:44 PM

Lots of great tips here!

-- God bless, Candy

View Jim Bertelson's profile

Jim Bertelson

4275 posts in 4499 days

#14 posted 07-24-2016 03:10 PM

Like the insert idea. I have a few sleds, but not one for 45 deg.

For miter bars, I use 3/4” wide, 1/8” thick aluminum flat and 1/8” hardboard in a sandwich glued with CA. Then use CA to glue to the sled. You can skip the screws entirely on small sled or miter gauge. I placed screws in addition for my super sled because of the amount of use and weight of the sled. Haven’t tried the plastic route yet, but I have read a number of posts about it.

I like Kiefer’s sliding panel sled idea and will keep it in mind for the next sled in a row…............

-- Jim, Anchorage Alaska

View oldnovice's profile


7764 posts in 4702 days

#15 posted 07-24-2016 04:23 PM

Good idea Roger, can’t wait to see the projects you make with that.
Again with the sawdustless shop pictures!

-- "Facts do not cease to exist because they are ignored." -- Aldous Huxley

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