In most shops, space is a premium. As a DIY-er with multiple interests, everything needs to be stored somewhere. I needed a crosscut sled that I can take anywhere and then store it when it's not in use. I also used the miter gauge that came with the table saw as one of the miter bars. So this is my solution. Feel free to improve what you may find more useful to you.
Build Time: 3 hours
(2) 3-inch screws For the blade cover
(2) 2-inch screws For the Miter gauge
For more details check out the plans here https://gum.co/PUYL
Step 1: Making the Fence
I used two 3-inch plywood sandwiched together (glued). Next, I ripped the plywood on the table saw to create a straight edge. The height can be as tall as you like -- all personal preference.
Step 2: Making the Miter Bar
To make the miter bar, I am going to use a digital caliper. This will help me measure and set the spacing for the table-saw blade from the fence. Carefully, rip the piece of wood using a push stick, and be sure to keep your hands and fingers out the way.
Next, cut a piece of wood for the rear support. Since the miter gauge is on one side occupying that slot, this will be for the other miter slot. Keep in mind you can make the back support whatever size that seems to be comfortable with you. I made mine compact. Cut the wooden miter bar down; this way it's not extended past the fence.
Step 3: Attaching the Miter Bar
Clamp the miter gauge to the fence. Dill and install the threaded insert (this allow you to attach and detach the miter gauge) without running the wood. Make sure you square up the fence to the framing square. Glue and attach the wooden miter bar. Be meticulous to get this as accurate as possible.
Step 4: Installing the T-Track
Step 5: The Blade Guard and the Dust Guard
At this point, the sled is nearly ready to go. Turn on the table saw and make your first cut, go all the way through. Then attach a piece of wood on the back side (closest to you). This wood can be as large as you like.
Note: The saw blade should never exit this piece. If you ever cut through this piece of wood, replace it!
Next, add a piece of plexiglass on hinges as shown in the photos. This will prevent the sawdust from flying toward your face. You can permanently attach, or make it removable as I did.
Step 6: Test
Here are a few test cuts I made if you are new to woodworking and need to get an idea of how this works.
About this jig.
- Make safe cut crosscuts on a table saw
- Repeatable cuts
- Made Dados
- Small footprint
- Use your existing miter gauge
- Hinged dust guard
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