This crosscut sled is great to have on hand if you don’t have a large shop or a lot of space for storage. Because of its compact size, it’s easy to take along with you to job sites and small projects.
About this jig:
- Make safe cut crosscuts on a table saw.
- Repeatable cuts
- Made Dados
- Small footprint
- Use your existing miter gauge
- Hinged dust guard
- Self-centering bits/ Hinges http://amzn.to/2qcyL7t
- T- Track Kit http://amzn.to/2qQMnrV
- Fence Flip Stop http://amzn.to/2qbzaeg
- Adhesive tape measuring tape http://amzn.to/2rOJc17
- Plastic spacers http://amzn.to/2rOAtMx
- Hex-head threaded nut http://amzn.to/2rvQ5Im
- Plexiglas http://amzn.to/2rxPVQF
- (2) 3in screws For the blade cover
- (2) 2in screws For the Miter gauge
- Scrap wood
- Small hinge http://amzn.to/2rzfKzS
- Digital caliper http://amzn.to/2qTCGJl
In most shops, space is limited. As a DIY’er with multiple interests, I need everything to have its place. I wanted a crosscut sled that I can take anywhere and then store it when it’s not in use. When I designed this crosscut sled, I was able to use the miter gauge that came with the table saw as one of the miter bars. Feel free to improve the design so it’s better suited for your needs.
To make the miter bar, use a digital caliper, this will help measure and set the spacing for the table saw blade from the fence. Carefully rip the piece of wood using a push stick, and be sure to keep your hands and fingers out of the way.
Next, cut a piece of wood for the rear support. Since the miter gauge is on one side occupying that slot, this will be for the other miter slot. Keep in mind you can make the back support whatever size that seems to be comfortable for you, I made mine compact. Cut the wooden miter bar down, this way it’s not extended past the fence.
At this point, the sled is nearly ready to go. Turing on the table saw and make your first cut, go all the way through. Then attach a piece of wood on the back side (closest to you). This wood can be as large as you like.
*Note: The saw blade should never exit this piece. If you ever cut through this piece of wood replace it!
Next, add a piece of plexiglass on hinges as shown in the photos. This will prevent the sawdust from flying towards your face. You can permanently attach or make it removable as I did.
Here are a few test cuts I made if you are new to woodworking and need to get an idea of how this works.