If you use a miter saw frequently and have trouble cutting through softwood, you may want to learn how to build a crosscut sle for your table saw. Not only will it make cutting into your projects more accurate, but it will also make your projects less stressful. Here are a few things to keep in mind while building your own crosscut sled for your table saw:
Avoid softwood for sled runners
When you choose to build a sled for your table saw, be sure to select materials that are tough and sturdy. You should avoid softwood, as it is prone to warping and can’t support the weight of your saw. Instead, use wood with a good elasticity to provide long-lasting sled runners. Wood should also be dimensionally stable and be at least one-fourth inch thick.
Generally, runners are made from strips of hardwood that must be thinner than the slot’s depth. They must also be positioned below the table’s surface. Some sleds require washers to raise them above the table’s surface. Once attached to the sled, test the sled’s alignment by sliding it back and forth. If it’s not level with the table’s surface, you’ll need to add washers to the runner’s edges.
Glue and screw a fence to the front and back of the sled
Using the wood screws provided by your table saw manufacturer, affix a piece of stabilizer board to the front and back of the sled. The sled will have to be adjusted for the width of the workpiece. If the fence isn’t adjusted properly, the final cut will be less than one-half inch wide.
You can adjust the fence on the crosscut sled by cutting slivers on all four sides of the piece. Start with the first side, and make sure that the edge is flush with the other half. If it isn’t, nudge the fence with a hammer to adjust it. Repeat this process for each side of the crosscut sled until the fence fits perfectly.
Calculate error per inch
There are many ways to calibrate the fence on your table saw. One method involves making five cuts with the saw blade. Another method involves using a feeler gauge. In the fifth cut, the fence is moved to the left or right depending on how accurate you are. Once the fence is set, it is crucial to clamp the sled tightly to the saw table.
The calculation tells you how much you need to adjust the fence. To make the adjustment, you must measure the fence from the pivot screw and edge of the sled. If the measurement is more than an inch, you can drill new holes. If you’ve drilled the new holes correctly, you’ll know exactly how much adjustment you need. If the measurement is not accurate, you’ll need to adjust the fence.
Attach miter bars
Attaching miter bars to a crosscut’sled’ for your table saw is an important part of your table saw setup. You can use them to hold the two halves of the sled together after the base is cut. You should set the fence height so that the fence faces are 1.25″ higher than the blade. This will prevent the blade from cutting the sled in half.
Place the sled on the table saw, and then lightly clamp it to the blade side of the miter gauge slot. Then, attach the front fence to the sled’s base using the pre-drilled holes in the runner. Let the glue dry for about 20 minutes before removing the assembly from the table saw. Don’t forget to scrape off any excess glue, since the sled can bind together.
Position a tri-square against the blade
The process of building a crosscut sled is straightforward. You simply position a tri-square against the blade of your table saw and label one side of the strip A, B, and C counterclockwise. Next, use calipers to measure the width difference between the front and back sides of the strip. Repeat this process with the remaining side of the strip.
To begin, align the fences. The fences will hold the sled’s two halves together after the base has been cut. Remember to set the fences perpendicular to the blade. For best results, position the fences as square as possible but move them when necessary. To make sure the fence is level, push it through the blade the first time. Then, make a mark along the left edge of the cut with a point.
