This is a step by step tutorial on how to build a cross cut sled. This project was very quick, easy and quite inexpensive to make. It took me from Friday at around 5pm worked till about 8pm that night and then finished up Saturday from about 10am to 12pm. If you are a serious woodworker or even a novice that wants to do more this addition into your shop will be worth its weight in gold. This also helps newcomers that maybe don't have a lot of different tools as this can take place of a sliding compound miter saw as well. Without further ado let's get started!!
1. First thing you are going to need for material is:
A piece of plywood of some kind that must be at least ¾" in. thick (I used mahogany as it was on sale) A strip of hardwood around 6' long x ¾" wide x 3/8" thick (purpleheart, oak, maple something hard that isn't as susceptible to swelling and contracting)2. Now rip your piece of plywood to 34" w x 30" long
3. Next rip your strips of hardwood down to fit into your table saw runners. This is probably about ¾" wide x 3/8" thick which is a fairly universal measurement for the table saw runners but double check your table saw just in case. You want these to fit snug with very little slack in it, it should slide freely but not very much side to side movement.
4. Once you have the pieces in the runners fitting nicely then place them in the runners and place your piece of plywood on top and make sure it is flush with the working edge of the table saw deck. Then put your square flat on the edge of the plywood and make a line for the center of the runner board and then carry that line the length of the board. Use this line to be able to drill your holes and use a counter sinking bit and screw it to the plywood from the face down, put between 4 and 5 screws into each runner.
5. Next cut 4 strips of plywood 4 ½" high x 27" long x ¾" thick
6. Now glue 2 boards together to make 2 handles 4 ½" high x 27" long x 1 ½" thick
7. Clamp them together and let the glue dry overnight
8. Now you have your handles for the sled created
9. Now mark out some cut outs that are approx. 7" from each end and 2" from the top. Use a coffee mug or round object to create a radius and use your jigsaw to cut it out. Do this on both handles, this allows for an easier grip for you to be able to work the sled with.
10. Now that you have that done sand it really good on all the edges and run it through your router with a chamfer or rounded bit just to break the sharp edge off so it's easier on your hands.
11. Now your handles and deck are complete now it's just a matter of connecting to two pieces.
12. First is make sure the deck is on your table saw and sitting in the runners and with your blade all the way down, turn on your table saw and slowly raise the blade till the teeth of your blade are sticking up about 1 tooth high then push the sled away from you till the blade is about 2" from the edge of the deck. DO NOT CUT IT ALL THE WAY THROUGH YET!!
13. Now place the handle that is on the user side of the table saw on making sure it is flush with the edge of the deck closest to you now place a clamp on there and use your counter flush bit and drill your hole and screw just ONE side of the handle for now.
14. Now that one side is attached take a piece of scrap and cut a small piece the same width as the kerf of your blade (mine was just shy of 1/8") but make sure its snug and it can sit in the slot by itself without being held.
15. Now take your biggest square and put an edge against the unattached side of the handle and the other side against the scrap piece you have stuck in deck slot. Now you can move the unattached side of the handle until it is perfectly square with the scrap of wood then clamp it in place and drill and screw it down with 4 - 5 screws.
16. The other handle needs no calibration, just make it flush with the edge of the plywood and drill and screw it down.
17. Now you can run your cut all the way through your sled and you are now finished!!
Congrats you have built yourself a cross cut sled for your table saw. Please check out the how to make a cross cut sled tutorial I have done as well if there is any confusion on the directions above.
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