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Introduction: Easy Table Saw Sled

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A table saw sled (or cross cut sled) makes cutting wood against the grain safer, and much easier. There are lots of technical ways to approach making a table saw sled, but sometimes you just need a simple and elegant solution to a problem. This is possibly the easiest cross cutting sled you can make, and it still achieves accurate cuts.

Cross cutting sleds (in case you didn''ll use the 5-cut method to check the accuracy of the sled once it''s make!

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Step 1: Tools + Supplies

This table saw sled uses scrap wood, relying on a few precise cuts and a for 1 last update 2020/08/06 very straight piece of hardwood. Here''ll need to make your own:This table saw sled uses scrap wood, relying on a few precise cuts and a very straight piece of hardwood. Here''ll need to make your own:

  • Calipers
  • Tri Square
  • Drill bits + countersink
  • Wood glue
  • Plywood (flat, and at least ¼""lazyload""https://www.instructables.com/files/deriv/FT4/LNTJ/IZ6CKFVY/FT4LNTJIZ6CKFVY.SQUARE3.jpg""/assets/img/pixel.png""lazyload""https://www.instructables.com/files/deriv/FPU/7LSL/IZ6CKG29/FPU7LSLIZ6CKG29.SQUARE3.jpg""/assets/img/pixel.png""https://www.instructables.com/class/Table-Saw-Class/""_blank""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step2""step""SMGPOBYIZ6C7H4B""step-title""mediaset""no-js-photoset""Measure Mitre Track""https://cdn.instructables.com/FZ5/K47O/IZ6C7CYQ/FZ5K47OIZ6C7CYQ.LARGE.jpg?auto=webp&frame=1&height=300""step-body"" wide x 0.375""lazyload""https://www.instructables.com/files/deriv/F2W/MFFH/IZ6CKGAH/F2WMFFHIZ6CKGAH.SQUARE3.jpg""/assets/img/pixel.png""lazyload""https://cdn.instructables.com/FOE/4T0D/IZ6C7CZE/FOE4T0DIZ6C7CZE.SQUARE3.jpg""/assets/img/pixel.png""http://d2n4wb9orp1vta.cloudfront.net/resources/images//cdn/cms/MMS_1009_GagingTips_Step.jpg""nofollow noopener""_blank""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step3""step""STSHLYPIZ6C7H7D""step-title""mediaset""no-js-photoset""Cut Track""https://cdn.instructables.com/F0Y/HCN8/IZ6CKGD7/F0YHCN8IZ6CKGD7.LARGE.jpg?auto=webp&frame=1&height=300""step-body""https://www.instructables.com/lesson/Ripping-Wood/""_blank""lazyload""https://cdn.instructables.com/FAQ/EADG/IZ6C7CZF/FAQEADGIZ6C7CZF.SQUARE3.jpg""/assets/img/pixel.png""lazyload""https://cdn.instructables.com/FKB/P23K/IZ6C7CZK/FKBP23KIZ6C7CZK.SQUARE3.jpg""/assets/img/pixel.png""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step4""step""SGOKVHLIZ6C7HAW""step-title""mediaset""no-js-photoset""Clean Up""https://cdn.instructables.com/F05/XFVH/IZ6C7D08/F05XFVHIZ6C7D08.LARGE.jpg?auto=webp&frame=1&height=300""step-body""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step5""step""S04YKNKIZ6C7H9B""step-title""mediaset""no-js-photoset""Test Fit Track""https://cdn.instructables.com/F74/Y28X/IZ6C7CZO/F74Y28XIZ6C7CZO.LARGE.jpg?auto=webp&frame=1&height=300""step-body""lazyload""https://cdn.instructables.com/F0S/4FLN/IZ6C7D07/F0S4FLNIZ6C7D07.LARGE.jpg""/assets/img/pixel.png""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step6""step""S35F3I4IZ6C7HCL""step-title""mediaset""no-js-photoset""Plywood Sled Base""https://cdn.instructables.com/FQW/V1MF/IZ6C7D0A/FQWV1MFIZ6C7D0A.LARGE.jpg?auto=webp&frame=1&height=300""step-body"" plywood that had very uneven edges - perfect for this application!

    This plywood base will sit on top of the track and be the bottom of the sled. Since it''s no need for it to be anything other than a flat surface we can cut through.

Step 7: Glue Base to Track

Woodworking Planshow to Woodworking Plans for Insert the hardwood into the mitre track.

Woodworking Planshow to Woodworking Plans for Apply a small bead of glue on the hardwood along the length making sure the 1 last update 2020/08/06 not to use too much or accidentally spill any glue onto the table saw. You only need a small amount of glue, since we''s approximately square to the track and the center of the plywood is in line with the saw blade. Apply a small bead of glue on the hardwood along the length making sure not to use too much or accidentally spill any glue onto the table saw. You only need a small amount of glue, since we''s approximately square to the track and the center of the plywood is in line with the saw blade.

Add weight to the plywood over the glue and allow the glue to dry overnight before moving.

Step 8: Secure Track

once the glue has dried slide the glued assembly out of the miter track and flip the plywood over.

Drill pilot holes along the hardwood length and countersink each drilled opening. Hand screw fasteners in each opening to mechanically secure the hardwood to the plywood. The glue and screw combination will ensure the two parts are mated securely.

It''s only job is to keep the structure of the sled once we cut the kerf in the plywood.

I used scrap wood glued along the front edge of the plywood, only making sure that the scrap wood was reasonably square so that the surface would glue correctly to the plywood.

Step 10: Cut Partial Kerf

Before gluing on the sled back fence, which needs to be square to the blade, we''ll be bringing the blade up through the plywood base to create a reference cut which we''s about 1""https://www.instructables.com/class/Table-Saw-Class/""_blank""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step11""step""S34YZQPIZ6CKI8H""step-title""mediaset""no-js-photoset""Select Wood for Sled Back""https://cdn.instructables.com/FOD/ELLX/IZ6CKG61/FODELLXIZ6CKG61.LARGE.jpg?auto=webp&frame=1&height=300""step-body""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step12""step""S3NJ265IZ6C7HKA""step-title""mediaset""no-js-photoset""Glue Sled Back""https://cdn.instructables.com/FW6/283D/IZ6C7D8M/FW6283DIZ6C7D8M.LARGE.jpg?auto=webp&frame=1&height=300""step-body""lazyload""https://cdn.instructables.com/FLA/1SZB/IZ6C7D79/FLA1SZBIZ6C7D79.LARGE.jpg""/assets/img/pixel.png""lazyload""https://cdn.instructables.com/FKZ/LDBH/IZ6C7DAL/FKZLDBHIZ6C7DAL.LARGE.jpg""/assets/img/pixel.png""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step13""step""SP1L65KIZ6C7IPG""step-title""mediaset""no-js-photoset""Examine""https://cdn.instructables.com/FM3/1OJC/IZ6C7I1S/FM31OJCIZ6C7I1S.LARGE.jpg?auto=webp&frame=1&height=300""step-body""lazyload""https://cdn.instructables.com/FE6/A7U0/IZ6C7I3G/FE6A7U0IZ6C7I3G.LARGE.jpg""/assets/img/pixel.png"" higher than the surface of the plywood and run the sled through the blade completely. your sled is functionally complete!

Now, how do we know it''ll use the 5-cut method, cutting a piece of scrap 5 times, rotating after each cut, to see the deviation from perpendicular.

By making multiple subsequent cuts on the same piece of wood, the resulting 5th cut will have magnified the error and show us our deviation.

Start with a rectangular scrap piece of wood and label each side 1-4 counterclockwise. This scrap piece doesn''x1''ll need to make minor adjustments to the back fence and redo the 5-cut method to check your adjustments.

Before going too far down the rabbit hole of accuracy I caution you to think about a few things.

Sled capacity

The 5-cut method is taking advantage of compounding the error with each successive cut, so the error you read on the 5th cut is not the same as a single pass.

Also, think about the capacity of your standard sled cut, it's probably not going to be a long cut, but a short cross grain cut. 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