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I have made two sleds for my table saw in the past for constructing
turkey box calls and used a couple reference books but mainly researched
YouTube videos detailing what other craftsmen had made. You certainly
find very creative and talented people via the internet who are willing to
share their projects and ideas free of charge. My main inspiration for
this forty-five degree crosscut sled was a YouTube video by
which detailed everything needed to build the sled.
I purchased a 4 x 8 feet sheet of 3/4 inch birch plywood which is
an overkill, whereas 1/2 inch thickness would be just fine and a length of 2
x 4 x 8 feet which was too damp and crooked as a snake and opted to use some
left over 2 x 4s that were dry, of which one piece was a little short but
worked out ok. The overall size of the crosscut sled is 24 x 36
It was about all this ole boy could do to transport
the birch plywood from my truck into the basement workshop since the ground
was wet and didn't want to drag the corner of the plywood in the wet ground.
My shop is far too crowded to rip the 4 x 8 sheet on my table saw which does
have an out rigger table but the width of my area is too narrow and had to
use a home made saw guide for my Milwaukee skill saw. After getting
the sheet of plywood sized up which I guesstimated the size according to my
table saw top and lets begin with a few photographs taken along the way:
The runner strips for the table saw miter slots are 3/4 inch wide x 3/8
inch deep and cut them from a scrap red oak board. I placed a few
pennies in the miter saw track to have the runners off the table saw top and
placed Titebond Original Glue on each strip and positioned the base of the crosscut
sled on top. I placed a couple large coffee cans that is filled with
solid lead wad cutter bullets harvested from a firing range with permission in Salemburg, NC
in 1979; talk about being a pack rat. Those coffee can lead weights
are heavy for certain.
Pix of penny in the track; used three in each track. After the glue
dried overnight, it was time to install the 2 x 4 cross members used to
reference the 90 degree crosscut, but first I wanted to add a few screws to
the oak sled/runner for extra security:
Drilled pilot hole and countersink all in one operation. Used 1 1/4 inch shortened dry
Table saw blade tilted to forty-five (45) degrees.
Sled was cut in two parts to install the rear and forward support for 90
Band sawing the crosscut side support member.
Crosscut sled supports about ready to install.
One screw is countersunk below the crosscut sled near the saw blade which will be the pivot
point allowing you to adjust the angle of the 2 x 4 to a ninety-degree angle
from the saw cut made on the sled. After the rear 2 x 4 is set to 90
degrees, it is clamped in place and screws countersunk in several places.
The sled is flipped over and the screws are installed; first a pilot
hole with countersink and then screws driven all the way in.
The sled was rotated 180 degrees and the other 2 x 4 was screwed into
place after it was squared to the saw cut made.
The other half the sled screwed in place. Everything is squared and
just clamped in place and installed the screws
Finished sled shown upside down.
Finished 45 degree crosscut sled ready for usage.
When initially adjusting the table saw blade to forty-five degrees, the
table saw has a 45 degree angle stop, however, when I relieved the tension
on the set screw the blade apparently moved slightly and didn't catch it
until after I made the 45 degree angle test cuts below which were off just a
hair. It is best to adjust the blade each time you plan on making a
forty-five degree angle cut instead of depending on the set-screw stop which
can get saw dust, etc. on it and change your angle setting a little.
My bad on this one, even though it was a test run. Better to test your
cut on scrap before destroying a high dollar piece of wood....grin if you
Since the table saw miter slots are not equally spaced from the saw
blade, you can rotate the crosscut sled 180 degrees and set it up to make a
ninety (90) degree crosscut by setting your saw blade back to 90 degrees and
get double duty from this crosscut sled.
This crosscut sled is definitely a must for making 45 degree angle cuts
on small boxes, panels and drawer fronts needing a 45 degree fit in the
vertical position, etc. which is different from the regular
picture frame 45 degree miter cut normally done from a horizontal position.
Web published by Bill aka Mickey Porter on 01-27-15.