Crosscut Sled Notes

Patrick Sullivan

I am showing the exact dimensions of the crosscut sled I currently use. However, many of
those dimensions are arbitrary and not critical. It could be moderately larger or smaller in both
length and width. I built it with American measurements, but if I built it with metric
measurements, I would round all the dimensions to convenient, even numbers.
The two things I would not adjust are the dimensions for the thickness of the materials, and
the height of the fence. 24mm ply can be made by gluing together two sheets of 12mm.
This jig is built for a table saw with a 10 inch blade (254mm). It anticipates that you will not
need a blade height more than about 2.5”, or 65mm, above the jig table top. If your saw uses a
blade with a significantly larger or smaller diameter, then some adjustments may be desirable.
These plans do not show the locations or size of the runners. These have to be individually set
to fit your saw. Select a durable hard wood for the runners. I use white oak.

The rear fence consists of two pieces of 1” or 24mm plywood

glued together at a right angle. There are two ways to do
A

Fence
this, shown in the drawings at the right. Drawing A shows a 2.5”
rabbet cut in the vertical piece. This makes it a little easier to Rabbet 63mm
glue the pieces together very accurately. However, simply
butting the two pieces together, as shown in drawing B, also
Base
works. Please note that you will need to cut the horizontal
piece to a different width to account for the presence or
absence of the rabbet.

Fence
B 2.5”
63mm

Base
The front “fence” or stabilizer can be attached to the base with
or without a rabbet. I don’t think it makes much difference
which method you use. However, please remember to adjust
the height of the stabilizer piece to account for the presence
(drawing C) or absence (drawing D) of the rabbet. C D
Stabilizer

Stabilizer

3.5” 3.5”
89mm 89mm
Base Base

Please refer to my YouTube video “Crosscut Tips and Strategies” for a discussion of the reasons for
the various features, and for photos of the completed jig.
 3.5”
6” 89mm
2” 1”or 24mm ply 9”
51mm 152mm 229mm

24”
610mm

½”or 12mm ply

19.5” 1”or 24mm

BASE
495mm solid hardwood

5”
127mm

2.5”
63mm
1” 24mm
Brace location

Brace location

4” 1”or 24mm ply

100mm 3”
76mm

1”or 24mm ply

Brace location
Brace location

This dimension depends on whether

it fits into a rabbet in the vertical fence
3” piece or not. We want the back of the 1”or 24mm ply 3”
76mm vertical fence piece to sit about 2.5” or 76mm
63mm from back edge of the base.
Small Locking Knob for Miter Gauge

7/8” knob 7/8” knob

3/8” drill 3/8” drill

22mm knob 22mm knob

10mm drill 10mm drill