This episode features a new crosscut sled built for the shop. The plan set and SketchUp drawings are available for download.
I found inspiration for this sled in books from my library and countless Internet searches. This simple project can be built in a couple of afternoons. A crosscut sled will increase safety, speed and accuracy of your crosscuts on the table saw.
The construction starts with a 3/4 MDF base. Incra miter bars are secured to the bottom of the base. These bars have an adjustment from the top that allows for a nice way to take up any slack in the miter slots.
The fences are 10/4 Maple. The rear fence is fastened to the base with 1-1/2 Kreg square drive screws.
The front fence is mounted with ¼-20 x 4 hex head bolts to steel threaded inserts in the MDF base. Oversized holes in the front fence allow for fine adjustment of the fence square to the blade. This feature makes realignment a snap.
A piece of T-Track is inset into the face of the front fence providing an attachment point for a stop block and hold down clamps.
I still have to build the top and rear blade guards.
I got a significant degree of inspiration for this sled from Gary Rogowski's Fine Woodworking article Build a Simple Crosscut Sled for the Tablesaw: Essential jig ensures square cuts.
Hopefully this will inspire a sled for your shop!