How to Make a Crosscut Sled | Simple Table Saw Sled

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In this video I’m going to show you how to make a crosscut sled to allow your table saw to make perfectly square cross cuts. This is a simple table saw sled but very functional. It incorporates a Powertec t-track and t- track stop.

I’ll cover cutting the slides, cutting the base, milling the fences and attaching them. Then I’ll show you how to attach the t-track and stop. Finally, we will cut the slot and wax the slides and base.

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Downloadable Plans ($4.99)

1/2" Birch Plywood

(1) STRAIGHT 2x4

Wood Glue

Wood Screws

T-Track and Stop https://amzn.to/30ivomf

CA glue and activator https://amzn.to/3mG6DYB

Wood wax https://amzn.to/3oVO2dQ

Rip down your slides so they fit your tracks without play but still slide smoothly. They should be around 1/16" proud of the table top. I used oak for better wear resistance.

Using 1/2" birch plywood, cut the base to the size you want your sled. The size is your own preference but I chose to make this sled 24"x18". You can also used 3/4" plywood or a different species of wood.

Put the slides in the miter slots aligned with the edge of the table. Position the table saw fence so the base is centered on the slides. Mark the location of the slides on the bottom of the base. Now apply a bead of CA glue on the slides and then spray the accelerator on your marks on the base.

Now butt the base up against the fence and then carefully lay it down on the slides.

Finally, drill and countersink holes and then screw the slides to the base. Be sure none of the screws are still proud or it will scratch your table saw when in use.

Mill down all 4 sides of your 2x4's for your front and rear fence. You should only be removing just enough to get full cleanup of the surface. This is to ensure the are smooth and straight.

Drill and countersink holes for your front and rear fence. Now glue and screw just the front fence in place, as shown. This fence is only meant to hold the base together after the slot is cut. It does not need to be perfectly square, it just needs to look nice. The rear fence will be attached later.

Put the sled on your saw and cut a slot from the front to about 2" from the back and stop. DO NOT CUT ALL THE WAY THROUGH YET!

Measure your t-track and cut a dado in the front of the rear fence so, when installed, your t-track is flush. Then mark the hole locations, predrill holes and screw the t-track in place.

Take extra care with this step! Put down a bead of wood glue where the rear fence will go and set the rear fence in place. Lightly clamp it down. Make sure the rear fence is square with the slot cut earlier in the process. Then you can tighten the clamp and screw down the rear fence.

Now, wax the slides and the base with wood wax so it slides smoothly on the table when using.

Now test the sled and check your cut to make sure you are making square cuts.

Now be amazed at what you were able to accomplish and enjoy safer, straighter cross cuts on your table saw!