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Thread: Big Ol' Crosscut Sled

  1. #1
    Join Date
    Oct 2006
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    Big Ol' Crosscut Sled

    I've been working on a fairly large cutting board, and I needed a way to trim the edges square. Since it was longer than my crosscut sled could handle, I slapped together a longer crosscut sled. I needed to use it today, so I figured I'd snap a few pics to show here. You'll see that I did no refinements. Eventually I'll likely sand it, ease the edges, and put a few coats of water-based poly on it, but for now I'm spending my time making products to sell, not pretty shop jigs.

    I started with a 2' x 4' piece of 3/4" oak plywood, and made the fences from 3 layers of 1/2" baltic birch plywood laminated together. The runners are UHMD plastic, bought from Peachtree Woodworking already cut to size. Stealing an idea from Glenn Bradley's (nicer) sled I saw here a while back, I made the front fence in such a way that I could adjust it. (Although once I had it tweaked just right, I locked it in with a handful of long wood screws.)

    Here's the sled, ready for work:

    Attachment 9383

    The wood on the edges of the cutting board is sacrificial pine that I used earlier in the construction process. Since the cutting board is too wide for my planer, I had to cut the initial glue-up in half before planing it (the long grain). I added the pine to the ends of each half so that when I ran them through my planer, any snipe would be on the waste wood, not the keeper wood. When I re-cut the wood and did the second glue-up, I left the pine in place, planning to trim it off after the second gluing operation, when I turned all the pieces to get the end grain orientation I wanted. After the second (final) glue-up, I sanded the whole assembly flat, then trimmed the edges.

    Attachment 9387

    Here's a picture of the bolt I used on one end of the front fence. The hole it's in is a bit wider than the bolt itself, allowing for some adjustment. The other end of the fence was attached with a wood screw, so that acted as a pivot point. This made is very quick and easy to set (and lock) a perfect 90į angle to the saw blade. I'll likely never adjust it again, but making it adjustable for the initial setting of the fence was a very useful addition. (Thanks for the idea, Glenn.)

    Attachment 9384

    The bolt is oval-headed for use in a t-track, but I used it because of the lower profile:

    Attachment 9386

    And one final shot of the bottom of the sled, showing the runners and the wood screws that I locked the fence down with:

    Attachment 9385

    As I said, this one's nothing fancy, but it'll allow me to safely crosscut pieces up to about 3' in width. (My other, smaller sled is a bit more refined, with t-track for a stop block, rounded corners, and a nice clear finish on it.)

    Pics of the finished cutting board will be ready after a few days of soaking in oil.
    When the going gets weird, the weird turn pro. - Hunter S. Thompson
    When the weird get going, they start their own forum. - Vaughn McMillan

    workingwoods.com

  2. #2
    Vaughn
    Dont bother to sand it, just send it over here.

    What kind of products are you making for sale?
    Myself in the process of building two 4' benches, hoping to be done this week. (Go faster if I get off this machine)

    WoodWorking, Crappie Fishing, Colts, Life is good!

  3. #3
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    Looks good, quick and dirty....... I like!!
    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.
    William Arthur Ward

  4. #4
    Join Date
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    Smithville, TX
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    Looks like it should work... I barely remember my crosscut sled days, trying to blot them out. Good job.
    Mini Max Tool Acquisition Mediator.
    "An old man to most kids and a young man to those who are dead."

    www.samantics2.com

  5. #5
    Join Date
    Dec 2006
    Location
    Punta Gorda, Florida
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    902
    My crosscut sled is great for most things but to small for about ten percent of the cuts that I need to make. In addition to my small sled I need one "Big Ol' Crosscut Sled" just like yours. (Need more room please) I do have the EZ but without buying a great big ole honkin' saw to go with it I cannot cut a full 1 1/2" depth with it on the rail.

  6. #6
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    Albuquerque, New Mexico
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    That's a manly sled!

    Vey slick, I need to make a big one like that.
    "I am enclosing two tickets to the first night of my new play; bring a
    friend...if you have one."
    --George Bernard Shaw to Winston Churchill

    "Cannot possibly attend first night, will attend second..if there is
    one."
    --Winston Churchill, in response




  7. #7
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    That's a beauty Vaughn. Now you know how I came to make that beast that you so kindly mention in your post; task specific need. You'll probably find it coming in quite handy for your larger cutting boards in the future.

  8. #8
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    Hey, I just noticed something..................

    You can see the floor in Vaughn's shop

    Last edited by Stuart Ablett; 06-05-2007 at 09:28 AM.
    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.
    William Arthur Ward

  9. #9
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    Quote Originally Posted by Stuart Ablett View Post
    Hey, I just noticed something..................

    You can see the floor in Vaughn's show

    Oh my gosh, you're right.

    Just a side note; I realized I'll be using my big sled once again tomorrow for some 33" end panels .

  10. #10
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    Quote Originally Posted by Stuart Ablett View Post
    Hey, I just noticed something..................

    You can see the floor in Vaughn's show

    And in my shop, too.

    I gotta say, the carpet's easy on the legs and knees, but it's a pain to keep clean. Also makes moving equipment on mobile bases a challenge.

    Quote Originally Posted by Sam Blasco View Post
    ...I barely remember my crosscut sled days, trying to blot them out...
    Fine. Rub it in, buddy. I'm trying to feel your pain, but it's just not workin' for me. I hope to someday be in your position.
    When the going gets weird, the weird turn pro. - Hunter S. Thompson
    When the weird get going, they start their own forum. - Vaughn McMillan

    workingwoods.com

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