DIY Table Saw Jig: Crosscut Sled – 5 Video Tutorials

A table saw is a versatile tool when used correctly.  A crosscut table saw jig is one of the ways in which you can increase the depth and diversity of the cuts you can make with your table saw.  A crosscut table saw jig allows for the use of a stop block for multiple similar cuts, and reduces the likelihood of injury due to uneven presser on the piece being cut.  When built the right way, a cross cut jig can also allow for angled cuts as well.  These videos go over multiple ways in which to build and add on to your crosscut table saw jig to fit your needs in your wood shop.

Making a Table Saw Extension and Cross Cut Sled | I Like To Make Stuff

Table Saw Crosscut Sled Video Summary:  

Bob is a fantastic teacher.  He goes over the reasons behind what he is doing and doesn’t waste time with fluff in his videos.  He is thorough and walks you through the project so that it would be very easy for anyone to repeat the process of building a cross-cut sled.  I would recommend this video to anyone who wants to build their own sled.

Table Saw Crosscut Sled Video Breakdown:

(0:12) – Explanation of cross cut sled, extension table, and shed;

(0:49) – Starting by cutting, ripping, and gluing plywood to eliminate warping; 

(3:02) – Cutting the plate for the bottom of the sled ; 

(3:48) – Pocket holes; 

(4:16) – Layout and installation of drawer slide for a panel to slide out of the storage area; 

(5:32) – Assembly of the bottom and side pieces of the storage box; 

(6:36) – Explanation of purposes behind box layout; 

(8:12) – Explanation of box attachment to table saw and leveling of the storage box; 

(8:50) – Cross cut sled design and purpose: to get cuts perfectly square; 

(9:50) – Cleaning up the laminated pieces; 

(10:17) – Attaching the front fence; 

(10:59) – Temporary attachment of the back fence to allow for adjustment, and sled runners; 

(11:53) – Sled runner design: tighter is better washers used to get the right height for the runners within the miter slot; 

(12:40) – Gluing the runners to the sled, attachment with screws, and sanding of the runner sides ; 

(14:50) – First cut through the sled and the addition of safety blocs; 

(15:45) – Back fence adjustment, and explanation of how to lay it out properly to get it square; 

(17:00) – Addition of fence supports and getting rid of the sharp edges with a router; 

(18:29) – Paste wax added to the bottom; 

(19:00) – 5 cut method to determine that the blade is perpendicular to the back fence; 

(19:53) – Leveling and attaching the box to the side of the saw; 

(21:14) – Layout explanation and assembly of wing for the table extension with collapsible brackets; 

(23:13) – Creation of slot for the sled inside the storage box; 

(23:37) – Installation of sliding storage wall, handle, and what things can be hung on the storage wall.

Unique Table Saw Crosscut Sled Video Clips:

(2:00) – He uses salt on the surfaces of the plywood he glues to keep them from slipping; 

(7:19) – He shows how he uses a backer board to drill holes to prevent blowout when drilling into the plywood; 

(9:30) – He goes over the importance of getting the back of the sled perfectly perpendicular and how to accomplish that; 

(10:39) – He notes the importance of countersinking the screw heads on the bottom of the sled so as not to scratch the top of the table saw; 

(12:04) -Explains why it’s important that the runners don’t touch the bottom of the table’s guide surface ; 

(16:22) – He didn’t glue the back fence in case he ever wants to adjust it in the future.

Build a crosscut sled: essential table saw jig | Steve Ramsey – Woodworking for Mere Mortals

Table Saw Crosscut Sled Video Summary:  

Steve does a great job explaining his process. He doesn’t add in a bunch of extra fluff when explaining.  He is direct and to the point in his in-depth explanation of how to make a simple crosscut sled for your table saw.  I particularly welcomed the things that he said were important to worry about, like getting the back fence perfectly square, and not working about the front fence so much.

Table Saw Crosscut Sled Video Breakdown:

(0:10) – Why cross cuts are difficult for repeat cuts;

(0:29) – A crosscut sled with two runners alls for many repeat cuts; 

(1:08) – New sled dimensions, gluing, and screwing of fences; 

(1:22) – Steel angle iron will keep the fence straight; 

(1:56) – Runners; 

(2:52) – Front fence installation; 

(3:22) – Rear fence installation, with pivot point; 

(4:27) – Fence  support and safety feature; 

(5:11) – Paste wax application.

How To Make A Crosscut Jig For Your Table Saw | DIY Creators

Table Saw Crosscut Sled Video Summary: 

This video is great to watch and he breaks down the how’s and why’s of the building process very thoroughly.  This version of a crosscut jig for your table saw is great for a small shop and for jobsites, as compared to large sleds that are bulkier to store and transport.

Table Saw Crosscut Sled Video Breakdown:

(0:24) – Cutting and ripping the plywood on the table saw;

(0:59) – Cutting and sizing the jig runners; 

(1:48) – Runner supports; 

(2:28) – Miter gauge attachment for this table saw jig; 

(3:09) – Attaching the runners to the jig; 

(3:48) – Using the router for the t-track slot; 

(5:15) – Plexiglass saw dust screen; 

(7:38) – Explanation of crosscut jig uses and set up; 

(8:32) – This jig is nice because its so small; 

(9:32) – Overview of project and what he liked and doesnt’ like about this table saw jig; 

Unique Table Saw Crosscut Sled Video Clips:

(0:35) – He checks whether he got a straight cut by how the board feels on his table saw after the cut is made to check its accuracy; 

(0:59) – Uses digital caliper to get the correct spacing between the saw blade and the rip fence; 

How to Make a Cross-Cut Sled | The Wood Whisperer

Table Saw Crosscut Sled Video Summary:  

Marc Spagnuolo, of the Wood Whisperer, expertly demonstrates why his is such a great teacher and how to build a crosscut sled for your table saw the right way.  I really liked how he gave specific tips on sled runner grain orientation and how to adjust the runners for the best feel on your table saw once finished.  Check out Marc’s full post on this video here.

Table Saw Crosscut Sled Video Breakdown:

(0:34) – Purpose behind the sled, its inherent safety, and when he uses a sled;

(3:39) – Materials he uses for this build; 

(4:37) – Plaining and cutting sled runners; 

(5:46) – Attaching the runners to the base with screws; 

(6:58) – Fence layout, cutting, and use of router; 

(7:45) – Cutting the Kerf; 

(8:04) – Installing the fence and getting the layout right; 

(9:10) – Checking square with the 5 cut squaring method; 

(11:04) – How to adjust the fence after checking the squareness to make it more square; 

(12:35) – Adjusting the runners if they rub after the installation of the fence; 

(15:31) – Techniques for how to use the cross-cut table saw sled with small panels;

(16:14) – Cutting larger panels; 

(16:38) – Stop block and batching cuts; 

(17:41) – Longer work pieces, using the fence as a stop block; 

(19:24) – Cutting smaller pieces on the table saw cross cut sled.

Unique Table Saw Crosscut Sled Video Clips:

(4:23) – He gives a great tip for having the grain of the runners be vertical to avoid expansion problems later on.

(19:24) – His solution for cutting smaller pieces on the table saw is genius and makes it really easy to safely do many small pieces.

Simple Table Saw Sled with FREE Plans | DIY Woodworking | Fix This Build That

Table Saw Crosscut Sled Video Summary:  

This is a very thorough and efficient DIY woodworking video that explains in depth how to make a crosscut sled for your table saw the right way.  He goes into detail on the construction and safety features of the sled that other videos don’t even mention. Overall its a must watch video prior to building your own crosscut table saw sled.

Table Saw Crosscut Sled Video Breakdown:

(0:37) – Sled base;

(0:48) – Fences; 

(1:37) – Glueing; 

(2:03) – Joinery and round-over on the router; 

(2:34) – Runners; 

(4:08) – Hand slots and fences; 

(4:55) – Fence slots for mini trak with the router; 

(6:05) – Extra slot added at the bottom of the fence face to help with saw dust; 

(6:46) – Fence attachment; 

(7:32) – 5 cut method and adjustment to ensure squareness; 

(9:34) – Stop block with spline and t-bolt kit; 

(10:47) – Safety feature to make sure that fingers and hands won’t get cut.

Unique Table Saw Crosscut Sled Video Clips:

(6:05) – I really liked how he added a unique extra slot at the bottom of the fence face to help with saw dust;

(8:10) – I like how he explained and demonstrated his method for adjusting the fence for squareness with a feeler gauge; 

(10:47) – I like how explained the dimensions and purpose of his safety feature at the back of the sled.