New Cross Cut Sled

[drumpriest]

Hi all, as some of you might remember I'm knee deep in kitchen cabinet work, but I got sidetracked when I discovered that I needed a new cross cut sled. It is finally done, I trued my miter slots (thanks to Tom Hintz's site), tested my TS for miter slot parallelism (within 0.003"), and made my new sled using Incra Miter slides.

Here are some photos.





Thanks to all who gave me advice on my miter slot situation. I mearsured it and discovered it was only out 0.005" over the run of the slots. Enough to make for a slightly off fit, but within tolerance from Powermatic, so they were not about to do anything. Some 400 grit sand paper on a block, and some time too care of the issue.

[lrogers]

That turned out real nice. You'll get a lot of use for it.

[JR]

Looks good, Keith.

Can you share a little bit about how you squared it up? I made one a few months ago using nuts and bolts through big, sloppy holes. This allowed for some adjustment of the rear fence before torquing it down. I don' notice any adjustment capaability in your setup, so thought I'd ask for your magic!

JR

[drumpriest]

Well, I was going to take a picture for you, but I'm being lazy at the moment. In short, the sled is adjustable, well, the fence is. Under the sled there are counter bored kreg screws coming up into the fence. One is the pivot, and the other 3 have wiggle room to allow for fine tuning the fence for square.

Things went well with this sled though, and it didn't need adjusting. First I tuned the slots, and tested them for parallel to the blade, then I tested the ripping fence to that slot. Then I positioned the ripping fence and held the bed of the x cut sled against the ripping fence. By doing this it kept the sled parallel to the blade. I then tightened the Incra runners (which you can do from the top, nice!). I then roughly positioned the fence at 1/4" from the back of the sled, clamped it and screwed it. Then tested the fence for 90 degrees to the blade, and it was dead on. Had it not been I have about 1/8" of play to repair it, but this one was so good it didn't need it.

[JR]

Thanks for the explanation. That's pretty much the same techique I used. The only real exception is that I had counter bored holes on top of the fence as well as uner the sled. I used bolts with nuts.

So why the crosscut seld for cabinet work?

JR

[poolhound]

Nice one Keith. My x-cut sled gets lots of use and is probably one of the most accurate (and cheapest) tools in my shop

I like your simple design. Did you consider removable inserts. The slot in mine is getting a bit ragged which is not helped by having 3 blades with different kerfs. When I get around to building version 2 being able to change the "slot" without having to build a new sled would be a great advantage - IMHO

[JR]

Did you consider removable inserts. The slot in mine is getting a bit ragged which is not helped by having 3 blades with different kerfs.

I've been pretty careful about using the same blade, so I don't have exactly the same problem, Jon. However on the sled I use to make the corner reinforcements on boxes (you know, completed box on edge, blade slicing across the corner - whatever that's called) I just taped a layer of 1/8" hardboard to the jig. Saves building a new jig and seems to prevent tearout.

JR

[poolhound]

I've been pretty careful about using the same blade, so I don't have exactly the same problem, Jon. However on the sled I use to make the corner reinforcements on boxes (you know, completed box on edge, blade slicing across the corner - whatever that's called) I just taped a layer of 1/8" hardboard to the jig. Saves building a new jig and seems to prevent tearout.

JR

Good idea, I was thinking of adding a layer of 1/4" MDF to the base and front fence of my sled. I cant seem to find dual faced hardboard nr me alhough I guess I havent looked very hard. I have always found the 1/8" hardboard a little flimsy for larger spans and wonder if it would lay flat and keep my fence sq.

[SARGE..g-47]

Nice un... that should give you some accuracy!

[RodKirby]

Consider a Lexan guard -AND- an "exit" guard - from one who is qualified to make the comment

I'd also recommend a travel stop.

[Bill in Buena Park]

Very nice sled Keith. Hope mine turns out as nice!

[pelligrini]

What's that device in the pocket on your stop Rod? Wireless something.. dust collector control?

[RodKirby]

What's that device in the pocket on your stop Rod? Wireless something.. dust collector control?

It's actually the start/stop for the saw - avoids reaching for the "stop", paricularly when ripping.

BTW - I have been flamed about this before

[siliconbauhaus]

Ever thought about making sleds and jigs for a living Rod? Another immaculate piece of work mate.

[RodKirby]

Ever thought about making sleds and jigs for a living Rod? Another immaculate piece of work mate.

Thank you for the kind words...

NEVER - it would take all the fun out of it