How to Build a Crosscut Sled

For those mundane repeated cuts on the table saw, every shop owner needs a crosscut sled. If you are to the point where one is necessary, building one should be a task accomplished with confidence. Most are constructed from medium-density fiberboard for the base of the sled, with different materials used for the runners and the fences. Build a basic crosscut sled to start--it is not difficult to add other amenities such as angle-cutting jigs later.

Things You'll Need

• Table saw
• Plywood (two inches by 64 inches by 3/4 inch)
• Medium-density fiberboard (two pieces: 18 inches by 32 inches by 3/4-inch)
• Framing square
• Variable speed drill
• 1/16-inch drill bit
• 3/8-inch countersink bit
• Philips head screw tip
• 1 1/4-inch wood screws, 20 pieces
• 2-by-2-by-36-inch square-cut lumber, 2 pieces
• 3/16-inch drill bit
• 2 1/2-inch wood screws, 20 pieces

Instructions

1. Cut the runners for the crosscut sled. Measure the width of the miter slots in the top of the table saw. Set the fence of the table saw accordingly and cut the 2-by-64-by-3/4-inch plywood lengthwise on the table saw. Cut that piece in half to give you the runners.

2. Measure for the placement of the runners. Put the two pieces of 18-by-32-by-3/4-inch fiberboard on a worktable. These are the base pieces of the sled. Measure the distance between the blade and the miter slots and add a half inch. Measure from one 18-inch side of the base pieces and make a mark accordingly. Repeat this on the other base piece as well.

3. Draw lines for the runners. Place the framing square on the marks and draw a line that is parallel with the 18-inch sides. Put the runners on the lines and trace the opposite edge of the runner on the base pieces. Drill 1/16-inch pilot holes for screws between the lines four inches apart. Center them between the lines as well.

4. Drill countersink holes and secure the runners to the base pieces. Turn the base pieces over. Drill countersink holes about one-quarter-inch in depth in the same place as the pilot holes. Hold the runners between the lines drawn and secure them to the base pieces with the 1 1/4-inch wood screws.

5. Square the base pieces with the table saw. Set the runner of one base piece in the miter slot to the left of the blade so that one-half inch of the base sticks beyond the blade. Cut off the excess wood and mark the base piece with an L. Repeat this with the other base piece only put it in the miter slot on the right side of the blade. Mark it with an "R".

6. Mark the base pieces for the fences. Place both base pieces in their respective slots and align the ends so they are even. Measure in from the ends and make a mark at four inches. Put the framing square on the marks and draw lines across the base pieces.

7. Secure the fences to the base pieces. Place the 2-by-2-by-36-inch lumber on the worktable. These are the fences. Set the combination square on one inch and draw a line lengthwise down the center of the two fences. Drill 3/16-inch pilot holes one inch from the ends and every four inches thereafter. Secure the lumber to the base pieces on the lines with the 2 1/2-inch wood screws.

Tips & Warnings

• Scrape the sides of the runners with a sharp chisel if they stick in the slots.

• Never raise the blade of a table saw any higher than needed for the cut.

References

• Wood Flooring: How to Make a Crosscut Sled to cut Medallions and Parquets

Resources

• Benchmark 20m: Crosscut Sleds