Cross-cut box for the Tablesaw

[Jediscroller]

With all the talk of tablesaws recently thought I'd share my plans for a cross-cut box for it. This makes cross-cutting much quicker, safer and makes for very accurate repeat cuts (think box sides). One word of caution....DO NOT attempt to rip pieces with it. I took a shortcut with a small piece once (ripping) even though I knew better and of course the wood pinched the blade, kicked back and thankfully I still have lightning reflexes and managed to get most of the way out of the way (it grazed my neck).
Anyhow here goes -

Material list:
Base: ¾ MDF – 18 ½ X 24
2 Runners: Sized to fit your saw’s miter slots X 18 ½ (Maple)
2 Fences: ¾ X 3 X 24 (Maple)
2 Top Reinforcement Rails: ¾ X ¾ X 7ish (I used scraps of the maple)

Instructions:

1. Cut parts to rough size.
2. Attach 1 runner approximately 10” from one end of the box using glue and counter-sunk screws. Use a carpenters square to insure the runner is perpendiculat to the edge. (photo 1)
3. Place the crosscut base and 1 runner into a slot on your saw. Carefully mark the location of the second runner.
4. Attach the second runner as above.
5. Lower your blade all the way and center your box over the blade. Raise your blade to it’s max height through the base. (photo 2)
6. Using the kerf as a guide, attach the fences relative to the kerf using a carpenters square. This is critical as this alignment will ensure perfect 90° corners. (photo 3).
7. Attach the top rails to the fences, centering them over the kerf. (Photo 4)
8. Raise your blade to max. height and feed the box through the blade. (Photo 5)

You now have a completed cross-cut box (photo 5). I occassionally will add beeswax to the runners to ensure smooth action when using the box.

[BobD]

Great design! Thanks for sharing Kevin!

Bob

[Pajaro]

Thanks Kevin. I will have to make one of those for my saw. Looks a lot safer than just using the factory miter that comes with the saw. I made one for 45 degree cuts some time back. But I still can't cut a good 45 miter cut with the jig or the radial arm saw.

[greatdane2]

Hi Kevin, the only thing I would add is a wide strip of plexiglass that would go over the blade from front to back of the jig. You can still see what you are doing but keep your fingers out off the blade.

[sawdustus]

Thanks Kevin. A solid design for a cross-cut sled. I agree with Alan about the piece of plexi or lexan to cover the blade path. I made one for myself when I first got my table saw and have almost worn it out with use. The next one will have two runners instead of only the one I put on the original.

george

[VB...]

Jediscroller great job!
Question:
The Top Reinforcement Rails are they strong enough to hold the sled together when you need to take the whole thing off the table?

I surfed the web for weeks until I found this site.
Super Sled - Crosscut and Miter Sled
Kevin they have a great way to set up 45 degree cuts. I will be incorporating this into my sled soon.




Mentioned it here:
New Old Saw - Part Two

VB...

[Jediscroller]

Originally Posted by VB...

Jediscroller great job!
Question:
The Top Reinforcement Rails are they strong enough to hold the sled together when you need to take the whole thing off the table?


VB...

VB,
My apologies...I just now saw your question. I've been using the sled for a couple of years with no problems taking it on and off the saw. The rails are had maple.

[ncsealeveler]

Thanks for the plans.Looks acurate.Tony

[VB...]

Originally Posted by Jediscroller

VB,
My apologies...I just now saw your question. I've been using the sled for a couple of years with no problems taking it on and off the saw. The rails are had maple.

No worries. Thank you for responding.
I have a similar table sled. Your right they are wonderful to work with.

VB...

[wwalker47]

Wow! That was an awesome design. I would like to make one for my table saw some day.

-Bill