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Improved Crosscut Sled Horn Lake MS

Crosscut sleds have been around for a long time, but few are ideal. Many are heavy and hard to store. Most develop an extra-wide saw cut in the fence and allow the blade to throw sawdust in your face. The following design solves all these problems.

The Home Depot
(662)349-6080
7260 Interstate Blvd
Horn Lake, MS
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(901)546-0226
3469 Riverdale Rd
Memphis, TN
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(901)818-0266
800 Truse Road
Memphis, TN
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(901)379-1535
4950 Stage Road
Memphis, TN
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

Fastenal- Southaven
662-393-2949
1868 First Commercial Drive Southaven, MS, 38671
Southaven, MS
 
The Home Depot
(662)890-9470
7740 Craft Goodman Rd
Olive Branch, MS
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(901)722-3535
1627 Poplar Avenue
Memphis, TN
Hours
Mon-Sat: 7:00am-9:00pm
Sun: 8:00am-7:00pm

Colco Fine Woods & Tools
(901) 452-9663
2631 Jackson Ave.
Memphis, TN

Data Provided by:
LOWE'S OF SOUTHAVEN, MS
662 536-3245
178 GOODMAN ROAD WEST SOUTHAVEN, MS, 38671
Southaven, MS
 
Lowe's
(662) 536-3245
178 Goodman Road West
Southaven, MS
Hours
M-SA 6 am - 10 pm
SU 8 am - 8 pm

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Improved Crosscut Sled

Improved Crosscut Sled

A split fence guarantees accurate cuts

by Tom Caspar

Whenever I want to make an accurate square cut, I reach for my crosscut sled. Unlike a miter gauge, its right-angle setting doesn’t need constant tweaking. My cuts are always right on the money. 

Crosscut sleds have been around for a long time, but few are ideal. Many are heavy and hard to store. Most develop an extra-wide saw cut in the fence and allow the blade to throw sawdust in your face. My design solves all these problems.

3 New Features

Take a look at these great features:

Zero-clearance subfence. The subfence is composed of two adjustable sides, like many router table fences. When the saw cut between the sides widens with use, simply remove the subfences, re-cut their ends square and re-install them. A zero-clearance slot allows you to quickly make a super-accurate cut. Just align a pencil mark on the workpiece with the saw cut in the fence and you’re good to go. A zero-clearance slot also eliminates tear-out.

Adjustable stops. Two stops mount on the sled’s T-track, making repetitive cuts very easy to set up. One stop is for short stuff; it only travels the sled’s width. The other stop is on a long arm; it’s used for pieces 18 to 48-in. long.

Easy storage. This sled stands upright on either end. In addition, this sled weighs only 24 lbs., making it easy to lift on or off the saw. A clear plastic guard over the blade keeps sawdust from flying in your face. Blocks behind the fence surround the blade when it exits the cut.

I’ve engineered this sled to give you years of reliable use. The fence and back brace are laminated to prevent twist or warp. They won’t sag because they’re stiffened by aluminum. The runners won’t be loose in one season and tight in another, unlike most sleds, because they only bear against one side of the miter slots. 

Sizing Your Sled

Stood on end, this sled is 31-in. tall and just fits under my saw. If you make a shorter sled to fit under your saw you’ll reduce the sled’s 24-in. crosscut capacity.

I used one full sheet (60-in. x 60-in.) of 1/2-in. thick Baltic birch plywood to make my sled’s base, which is 36-in. wide and 31-in. deep. If you’re willing to give up 1-in. of crosscut capacity, you can make the base from one half-sheet of Baltic birch plywood (30-in. x 60-in.). 

Make the Base

1. Cut the base (A) to size. 

2. Make the runners (B). I made mine from the same material as the base: Baltic birch plywood. It’s 1/2-in. thick, but the runners must be 3/8-in. thick. To make the plywood thinner, cut a piece 4 in. wide by 33 in. long. Remove the tablesaw’s guard, raise the blade 1-in. high and set the fence 3/8-in. away from the blade. Stand the plywood on edge and rip both sides. Replace the guard, lay the plywood flat and cut the runners about 1/32-in. narrower than the miter-gauge slo...

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