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Thread: New Cross Cut Sled - Finally Done!

  1. #1
    Join Date
    Mar 2007
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    WNY, Buffalo Area
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    873

    New Cross Cut Sled - Finally Done!

    I set about making a cross cut sled, and I am almost done. I "borrowed" some ideas from here. Thanks for the good Ideas Glenn !
    http://familywoodworking.org/forums/...ead.php?t=3370

    I also added some things that I thought might be handy.
    Some extras that I added are:
    -Adjustable front and rear fences - this made squaring up the fence very easy - swiped this one from Glenn

    -Handles - so I don't have to grab the fence possibly throwing it out of square.

    -T-Track in the fence - for use with a stop block for repeated cuts.

    -Zero Clearance Insert for standard blade & Dado use - another swipe

    -T-Track mounted into the sled for integrated material clamping up to 8 1/4in widths. This can be extended in the future if the need arises.

    -The clamping blocks are built with a lip that over hangs the edge of the sled to keep them from twisting when they are tightened down.

    -If you flip the clamping blocks over they can be set as guides to allow for mitered cuts.

    Not an extra, but a very good idea, I put the runners in the miter slots with double stick carpet tape on them, then butted the sled up against the TS fence and lowered it on to the tape & runners. Thanks again, Glenn.

    I have already started waxing the bottom and runners. The only thing left is to attach the ZCI to the sled.

    Edit:
    Materials Used:
    sled - 3/4in birch ply
    fences - pine (milled down from a 4x4)
    clamping blocks - white oak
    stop block - 3/4in birch ply
    ZCI - 1/4in birch ply
    T-Track & knobs - from Rockler
    Toilet bolts - used in fences and with T-track
    Last edited by Sean Wright; 07-26-2007 at 04:52 AM.
    We create with our hands in wood what our mind sees in thought.
    Disclosure: Formerly was a part-time sales person & instructor at WoodCraft in Buffalo, NY.
    www.tinyurl.com/thewoodshoppe

  2. #2
    Join Date
    Oct 2006
    Location
    ABQ NM
    Posts
    29,079
    Very nice job, Sean. I like the hold-downs. (My smaller sled has the t-track on the front fence like yours...very handy.) BTW, it's not swiping...it's borrowing ideas. I can say that, because I've swiped...er...borrowed a few of Glenn's ideas, too.
    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

  3. #3
    Join Date
    Nov 2006
    Location
    Constantine, MI
    Posts
    6,975
    Sean,

    Coolest CCS I've seen. Well done! Love the t-track and clamping block idea. Beats my 1/2" ply with 1x2 back fence by a mile.
    “We all die. The goal isn't to live forever; the goal is to create something that will.” - Chuck Palahniuk

  4. #4
    Join Date
    Oct 2006
    Location
    Placitas, NM in the foothills of the Sandia Mt
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    688
    Hey Sean,
    That is the mother of all sleds!!
    Don't believe everything you think!

  5. #5
    Join Date
    Dec 2006
    Location
    Punta Gorda, Florida
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    902
    Very nice Sean! I guess that you would laugh if you saw mine. Extremely useful none the less.

  6. #6
    Join Date
    Nov 2006
    Location
    Delton, Michigan
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    17,231

    mitre setup?

    hey sean have youhad achance to try out the mitre part with setting it up from the speed square? just curious as to how well its does on the mitres? other than that i like yur sled alot and might be doing something similar in the future
    If in Doubt, Build it Stout!
    One hand washes the other!
    Don't put off today till tomorrow!

  7. #7
    Join Date
    Mar 2007
    Location
    WNY, Buffalo Area
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    873
    Quote Originally Posted by larry merlau View Post
    hey sean have youhad achance to try out the mitre part with setting it up from the speed square? just curious as to how well its does on the mitres? other than that i like yur sled alot and might be doing something similar in the future
    Thanks everyone!

    I haven't had a chance to cut anything on it yet. I still have to get the inserts attached....only so many hours in the day.

    What I was thinking about doing for the miters, was to make something along the lines of a block that over hangs the edge of the sled (attached to the end of the guides). It would be at a predetermined angle (like 22 1/2, 30, or 45) so that when it is tight against the side of the sled it will keep the miter guides from twisting. I'm not sure if that makes any sense to anyone, as I find it hard to explain the concept.

    I have a CMS already so I'm not in a big hurry to get miter portion done. I set up the picture mostly to show the potential capability of the sled.

    When I get the insert in, I will give it a few test runs.

    Future enhancement:
    I was also thinking about adding a box joint jig, attached to the T-Track in the fence, used with a dado stack. With it being attached to the T-Track, that would allow for great deal of adjustability.
    We create with our hands in wood what our mind sees in thought.
    Disclosure: Formerly was a part-time sales person & instructor at WoodCraft in Buffalo, NY.
    www.tinyurl.com/thewoodshoppe

  8. #8
    Join Date
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    No, not all of SoCal is Los Angeles!
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    Sean, that is sweet. I've always meant to go back and cut handles in mine to avoid the 'fence grab' as you describe. I've never gotten to it. Thanks for shaming me into motion on this.

    As far as borrowing ideas, that's why we're here. Glad something I posted helped others. Believe me I borrow liberally from anybody who is willing to share. A sled is one of my most used jigs and has saved time and money well in excess of what they took to build.
    Any sufficiently advanced technology is indistinguishable from magic.
    - Arthur C. Clarke

  9. #9
    Join Date
    Mar 2007
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    Additional Enhancement Idea

    In building this sled I was looking to make an all purpose sled. I didn't want to make it too big, as to be a pain to use. Essentally with the materials I had I could have made it deep but some what narrow or wide but not able to cut deeper pieces.

    I have been thinking about how to extend the lenght at which the stop block can be used for repeated cuts. Currently it maxes out at 12in to the right of the blade. I built the sled with more capacity to cut wider pieces (up to 24in), than stops for longer pieces.

    So what I am thinking of doing is taking a long piece(at least 3 1/2ft long) of white oak, ripping it down to about an 1in wide. Then gluing a block on the end creating sort of an "L" shape. Then drilling 1/4in holes every 6 to 8in. The holes would allow for me to use 2 or more T bolts/star knobs to hold it in place, against the T-Track in the fence. This would let me adjust the stop to extent out to about 3 feet from the blade on the right side.

    The only down side that I am seeing to this idea is that there is currently nothing to support the end of the work piece. I would either need to come up with a way to support the end of the piece or a way of clamping it straight down on to the sled. If I can support the end of the piece, the clamping pressure from the clamping blocks should be enough to keep it from lifting off the sled.

    Hmmmm.... the gears are turning..........
    We create with our hands in wood what our mind sees in thought.
    Disclosure: Formerly was a part-time sales person & instructor at WoodCraft in Buffalo, NY.
    www.tinyurl.com/thewoodshoppe

  10. #10
    Join Date
    Mar 2007
    Location
    WNY, Buffalo Area
    Posts
    873

    Done at Last! The Super Sled

    I've been wanted to get down to the shop for more than 10 minutes here and there since I started my cross cut sled, and tonight I finally got the chance.

    I wrapped up the last few things I wanted to do on it, so now it is done and ready for work.....

    In the tradition of several other members, I have decided to name it. While it is not a tool, with a motor like the Phoenix, it is something that I will get a great deal of use out of. Going forward, the sled will be named "The Super Sled"

    The final touches included the following:
    -Make several extra ZCIs, some for dados and some just for extra
    -Attach the ZCI
    -Make an extended stop block for repeated cuts over 12 in in length.

    Not much to say about the ZCIs, pretty straight forward. The only thing to note is that I made them with a tab that sticks out from under the main fence. With any luck, and being extra careful, I can avoid cutting through this tab. This way if I want to change ZCIs from a regular blade to a dado, I don't have a ZCI in 2 pieces (Hopefully )

    The extended stop block
    This is made of white oak. It will let me set a stop any where from over 12in up to 36in. For 12in and under I use the small stop block pictured in the initial post. It mounts to the t-track in the fence with T-bolts and nuts. I couldn't use the knobs as they interfered with the stock being cut. I drilled holes in the extension arm every 4 inches. This way I have a great deal of flexability in adjusting it. It for whatever reason, I need to set it to the left of the blade, all I have to do it just flip it around.
    As an example oh how it works:
    The picture of the extended stop block in use, it is set for a 20in cut.

    I tried it out, and it worked very well. I'm sure that it helped that I had already loaded the runners up with Johnson's paste wax. The clamp blocks worked exactly how I had hoped. Using both clamp blocks you don't have to worry about the loose cut off moving around after the cut.

    The only thing I would change at this point, would be to move the t-track up higher on the fence. This would allow thicker stock to be cut using the extened stop block set up. Not a huge deal as I can still cut long stock on the CMS.
    We create with our hands in wood what our mind sees in thought.
    Disclosure: Formerly was a part-time sales person & instructor at WoodCraft in Buffalo, NY.
    www.tinyurl.com/thewoodshoppe

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