A table saw is great for making different types of cuts. It has the ability to rip cut long materials, and also you can efficiently crosscut wide materials with it. Moreover, it has the capacity to make miter cuts up to 90-degrees on narrow boards.
But, how can you make accurate crosscuts with a table saw? It can be done with a table saw sled. Yes, you heard it right. If you have a table saw seld, then making clean and accurate crosscuts won’t be a hassle. If you don’t, then learn how to make one.
In this article, we have shared the table saw crosscut sled plans with steps so that you can create an excellent table saw sled to make miter and crosscuts.
Steps to Create a Table Saw Crosscut Sled
Collect Materials and Cut Them
Start with gathering the materials you require and then cutting them accordingly. Make sure all the materials are high-quality ones and the plywood is flat and smooth.
Let’s begin with the tricky parts that are cutting the runners, which can slide smoothly, and getting an accurate fence. Start by cutting a few chunks of plywood for making the blade cover, front fence, and stiffener.
Make sure to cut the plywoods ¼-inch wider and ½-inches longer than the actual measurement for trimming. Next, spread some wood glue on the pieces, correctly line them up, and then clamp them together. After a few minutes, you have to scrape off the partially spattered glue.
Now remove out about ¼-inch from the chunks by running them through the jigsaw. Now with a belt sander, make both the pieces smooth.
Runner and Base
Now, you need to cut the runners from the piece of hardwood. The smooth movement of the board will depend on the runners, so make sure they don’t create any interruption and smoothly slides in the miter gauge slots.
If the miter gauge slots are ¾-inch, then sand or plane 1×3 piece of hardwood and check whether it slides smoothly or not. If it moves slightly, then it is accurate.
Next, add some glue to the pieces and wait for about 20-mins to set the glue. Then, from the table saw, remove the stuff and scrape off the excess glue from the bottom of the base and the edges of the runners so that they don’t interrupt while moving these runners back and fro.
Also, make sure there is no glue stuck in the slots. Now slide the sled continuously to check if there is any interruption. If there is any problem with the movements, then take a piece of 80-grit sandpaper and attach it to a square block of wood.
Now with it sand the areas of the runners that cause the interruption and keep doing it until they slide smoothly.
Stiffener and Fence Attachment
Now place the stiffener at the front edge of the base and attach it by gluing and screwing it. But make sure to be careful while screwing the base and keep the screws far away from the blade of the table saw. It can damage the blade.
Next, place the table saw blade about ¾-inch high and slide the base into it. Stop the blade at the ending point that is 3-inches back of the base. After that, turn off the saw and slowly carry away the sled from the table.
Now, take the fence and align it accurately with the end edge of the base, and then into the right end of the base, attach a screw. Clamp it securely after measuring the 90-degree angle of the fence with the blade. Carefully screw the blade cover with the fence from the bottom of the base.
For measuring the object, you can add a measuring sticker on the fence.
Make a Test Cut
After attaching the stiffener and the fence, it’s time to test it. Place a 12-inch or larger piece of plywood on the sled for cutting. Cut the piece of plywood into two, and then inspect them. Flip over one part of the cut wood and put it together with the other freshly cut part to check the accuracy.
If you don’t see any gap between them, then it means the fence is perfectly square. So you can embed some screws into the fence to tightly hold it in place. If there is a gap between the two pieces, then tap the fence with a hammer. Keep making test cuts until you get accurate cuts.
Attach The Stop Blocks
After completing the above table saw sled plans, you need to install stop blocks to prevent the table saw blade from cutting the sled cover. So it is quite essential to add stop blocks. Screw them on the bottom of the sled and you are done.
So these are the complete steps of a table saw crosscut sled plans, you can easily follow them to make your own sled.
Materials Required for Making a Sled:
- Wood glue
- Carriage bolts and nuts.
- Sand Paper
Tools Required for Making a Sled:
- Table saw
- Tape Measure
- Belt Sander
- Drill set
- Wood Chisel
Frequently Asked Questions
1. What is the purpose of a table saw sled?
A table saw sled is mainly used for cutting hardwoods in several pieces and at various angles smoothly.
2. Can I make a sled and fence with any wood?
You won’t get the desired results if you make a sled with cheap quality wood. Always try to use high-quality wood like Plywood or MDF for making a durable sled and fence.
3. Will the sled be able to cut at a 90-degree angle?
Yes, a sled can sharply and effectively make a cut at a 90-degree angle.
If you are a beginner and want to make a sturdy and durable sled, then follow the above steps of the table saw crosscut sled plans correctly. These steps are easy to understand and follow. All you have to do is read them attentively. Also, make sure to work carefully and wear all safety equipment.