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Sunday, November 6, 2016

Shop Project - Make a table saw cross cut sled - Important jig for accuracy


One jig you should really make for your table saw is a cross cut sled. It will improve your accuracy and ability to make repeatable cuts. Whatever you are making, it will make things much easier. So after about two years with this saw, I finally got around to making a cross-cut sled. I even used the 5 cut method to check the accuracy of the fence.



I measure the slots with calipers and transfer the dimensions to the fence.


After some fiddling I get some cuts from the 1/4 inch plywood that fit well in the slots.

As I add some nuts to the slots to rails to raise the runners for gluing.

After the glue dried I add some screws for reinforcement and cut off the excess.


For the back rail, I used a piece of 2 by 4, cutting off the rounded edges.

I laminate 2 pieces of plywood for the fence and square up the ends.

I attach the back rail and make a partial cut.

I add a piece of 90 degree aluminum to hold the fence straight.


I cut off the excess aluminum.

I attach the fence, realize I had it backwards, and attach it again.

After attaching one side, a line the fence up with the kerf with a  square, clamp it, and attach the other side.

I test it using the five cut method. I'll link to some videos that explain it better than I could.


Here are some videos that explain the 5 cut method in detail.

https://www.youtube.com/watch?v=uE9f4bp_wm8
https://www.youtube.com/watch?v=1eL79CJ6XHQ
https://www.youtube.com/watch?v=UbG-n--LFgQ

I think that's close enough for me. I will add some more screws to the fence, and a block as a blade guard for some additional safety.


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