How To Build A Crosscut Sled For Table Saw: A Quick Guide

The table saw accessory known as the cross-cut sled can be made in four steps which include the components; a Crosscut Base, a Back Fence, a Front Fence, and a Runner. You must follow the below-mentioned steps to be able to successfully learn how to build a crosscut sled for table saw.

Step #1: Choose the Materials For Crosscut Sled Components

Back Fence and Front Fence:

Materials:

For a rear fence, we recommend plywood because of the simple fact that it is strong, light, durable, and resistant to warping. But, it is not the only option for your rear fence. If the right tools are available, then feel free to use hardwood as well.

Just never use softwood under any circumstances. Not only is softwood less durable for your table saw, but it can also easily warp, which is bad for your back fence.

Dimensions:

When we talk about the dimensions of a table saw fence, then we primarily mean the height of the said fence. Ensure that the fence is tall enough in proportion to your table saw model.

If not, then safe to say that you might chomp your sled in half. If necessary, the fence height should be such that you can use the table saw blade at full height if you have to.

Learn more about the table saw’s fence here.

Base:

Materials:

The best option we recommend for your table saw is plywood once again. The material is both smooth and flat. Not to mention the varying sizes available are very suitable when it comes to the processes involved in building a sled base.

However, make sure that it does not warp. Better to prefer only the best quality plywood.

Dimensions:

Whether you want your sled to be big or small or something in between, make sure to choose the dimensions carefully. The size of the base decides the size of your entire table saw sled and it should be according to your table saw.

If your table saw is large, then a large sled, but if your table saw is small, then obviously a small sled. Remember, whatever the size, a sled base must always be perfectly square.

Runner:

Materials:

We recommend hardwood. Again, softwood just doesn’t cut it, and plywood is nice, but it can wear relatively quickly. So the best option left is hardwood. However, maple is most common among DIY table saw users.

Dimensions:

There is not much specific to note about runner dimensions for your table saw. They vary and depend on the previous two components mentioned above.

Step #2: Start Building

Using quarter-inch plywood, rip apart your sled runners and fit them accurately into your miter slots. It will take some tries to do this, so don’t stress yourself too much.

Ensure that the runners don’t fit into the miter slots too tight. Allow for sliding movements without wiggling. Ironically, we recommend you fit them tight initially but then sand off all the edges using sandpaper.

Use wood glue to glue the runners onto the base. More specifically, the underside of the sled. Make sure that the runners are slightly raised by stacking coins in the miter slots. When done, leave to dry for 40 minutes.

Finally, add reinforcements. The best way is to drive screws into the runners but not too deep such that they protrude out onto your table.

Note: We recommend checking out our guide on building a miter saw table to help you out as well.

Step #3: Make The Fence For Your Sled.

As you wait for the runners to dry, start working on your sled fence. A fence has two parts, as mentioned above: a back fence and a front fence. Or you could say that you have two fences.

Either way, the fence closest to you must be right-angled to the blade, while the rear fence will hold the sled together with the base.

This can be achieved by joining two three-quarters an inch of plywood strips together using wood glue and screws. The screws are for the front fence. More specifically, joining said front fence in perfect alignment with a steel-angle iron.

On a side note, once you’re done building everything, remember adjustment is essential, too. You can use the guidelines presented in this guide: Learn how to adjust DeWalt table saw fence.

Step #4: Attach The Fence To Your Sled Base.

Once the already-used glue has dried up, attach your fence to your sled base. Unless you plan on using your table saw sled from both sides, don’t worry about the perfect dimensions.

Unfortunately, we cannot say the same about your front fence. It is the most important part of your sled and also the first thing that you will attach now. Other than the runner, of course.

First, you clamp the base for your pre-drilled holes where your screws will go. Take absolute care here because you do not want these screws to be where your blade is going to work. Keep them away from the blade path.

Then, mark the pre-drill holes and drill through them, only through the base, not the fence.

After that, cut through most of the base as well as the front fence but just before the back edge. Once again, clamp your fence, or you could simply align it via a set square.

Finally, screw only one end of the fence. Leave the other hand because you will use it to hold the fence down. What’s the point of this one screw? A pivot as you turn and test until the fence is perfectly square. Then, drill in the remaining screws.

Preparing to Attach The Fence To Your Sled Base

FAQs:

Why do you need a Crosscut Sled?

There are two types of cuts when it comes to DIY; rip cuts and cross cuts. Rip-cutting involves cutting parallel to the wood grains, whereas cross-cutting refers to perpendicular to the grain. These are the basics of woodworking with table saws, in fact, and you can learn more about these by learning how a table saw works.

Nevertheless, the thing is, most table saws are well-suited for rip cutting by design. Cross-cutting? Not so much. Yes, a miter gauge is supposed to handle cross-cuts, but it falls short. Literally. What’s more, is that your workpiece has little to no support from the table saw.

Not to mention how dangerous it can become. Some DIY people use a screwing board to lengthen their miter gauge by attaching it to the face, but it is a temporary solution at best. After all, you will still only have a single runner for the miter slot.

And lastly comes repeated inaccuracies. A miter gauge is meant for angled cuts, yes. However, one cannot achieve a perfect right angle repeatedly as one goes through several jobs. What results are rougher cuts which are something we all prefer to avoid.

An accurate cross-cut sled, however, will not be a temporary solution. Repeatable clean cuts, high accuracy, safety, and stop-block, meaning all these repeatable cuts can be of the same length down to the millimeter.

Of course, other factors may also play a role, such as the height of the table saw, but those are separate concerns. You can, however, learn more about it here.

What does a Crosscut Sled Design include?

A table saw crosscut sled has four components:

Crosscut Sled Base: It is simply for the workpiece to rest on the table.
Crosscut Sled Back Fence: Perfectly square and flat, a back fence or rear fence helps in achieving accurate cuts with the table saw.
Crosscut Sled Front Fence: A supporting role, a front fence simply glues the base pieces together against the table saw.
Crosscut Sled Runners: For accurate cuts, the base must be allowed to slide on the table saw without any wiggles. A runner does just this, which is why it is the most important part of a sled.

Conclusion

And now you’ve learned how to build a crosscut sled for table saw, and have the final version of your crosscut sled (hopefully) in front of you!

Yes, we admit that the process is a bit more complicated than normal, but the rewards are worth it. You will make yourself an accessory and hence, won’t have to buy it. Even more, you’ll get the perfect means to achieve accurate and repeating cross-cuts.

Good luck with the build! You can also check out a more practically displayed video on building a crosscut sled if you want more hands-on learning, too!