How to Build a Table Saw Sled || Table Saw Cross Cut Sled

[@Bourbonmoth]

Thanks to Bespoke Post for sponsoring this video! Head to bspk.me/moth and use code moth20 to learn more and get 20% off your first box.

[@chadsmith2180]

Cool sled, gotta stupid question, probably. Anyone ever tried using pop rivets in wood?

[@sarah-janegalipo3995]

They don’t ship to Australia 😕

[@karl_alan]

I just realized we are only about a half hour drive apart. I would love to collaborate with you sometime when the world gets back on track.

[@brandondorch8560]

Boo more boat!

[@littlebrother82]

For the sacrificial fence part, the last place I worked had a clever solution for that. They used a T-slotted sacrificial fence (I don't know if they made it themselves or not), then in the backer fence, a couple T-bolts stick out to tighten it down by hand from behind. So as you need something to be zero clearance, you can slide the sacrificial fence into the blade path 1/8" at a time, tighten it down, and cut, very handy. Of course, this consumes the sacrificial fence little by little, but it's over the course of years, and is easily replaced. Hope I explained that properly, it's the best system I've seen.

[@katzmosestools]

Great stuff! Thanks for the shout out bud! Glad you like it!

[@Chev56]

I grabbed one of those stops over a year ago... it’s awesome (the apron is not bad either, JKM 😉)

[@katzmosestools]

@@Chev56 thanks brother!

[@twilocki]

I love mine. That have proven to be most useful.

[@chadstoudt2580]

I'm definitely buying one soon. I've been wanting that stop for at least a year now haha.

[@tomdraper3206]

Im getting one of those woodworking aprons at Christmas time for sure!

[@mulchman2000]

The "crap" you have lying around your shop is way nicer than the crap I have in mine...

[@JohnC1]

I've gotta make my sled out of dried leaves, cobwebs, and some baby toys.

[@jaydenshepherd8348]

Yea the the back t track is 50 bucks with the clamps being 15 a piece like fu$& that sled is expensive

[@mrose4132]

It’s nicer than the stuff I buy!!!

[@LordHolley]

One man's crap is another man's.....idk.

[@jasonfurl7207]

That’s for sure- I can usually make something nice out of the crap I have laying around, but mine look more like a science fair project than a slick setup like this

[@halsti99]

for anyone that has a saw stop, or other safety saw: If you cut aluminum, it will trip your system. so make sure it never touches your saw blade, while the system is active. most saws have a bypass mode to let you cut it. also, if you make a sled like this, notch out a bigger area of the aluminum track, so it never touches your saw, while in use.

[@vikassm]

Yep!!

[@frankscandura8377]

You can also place the saw stop in bypass mode to cut aluminum

[@essextwo]

The world needs more comments like this. I'd have not thought about this until I encountered the problem. Thanks.

[@robbieplankenhorn2580]

To add to this, when you place your saw in bypass mode, it’s only good for just that cut. When you stop the blade and start it again, it won’t be in bypass mode anymore.

[@carsntoolsmcgee4570]

I JUST got one and wouldn't have even thought of this. THANK YOU!!!!!

[@DavidCarrick-d2s]

Retired 47 year law enforcement veteran looking for a hobby and your videos helped me decide. So many other show tools and their capabilities, how to buy from them and very little about actual woodworking. Keep them coming. I enjoy watching and learning from you. Dave from Georgia

[@shanekwilson648]

every time I watch one of your videos I immediately run away and spend money. Great ideas!

[@bruceverhulp6230]

Hey, Jason thanks so much for all your how-to videos, I just got into the woodworking hobby by force, my daughter needed a table/counter extension for her new apartment. It had to be an exact fit, so I thought what the heck give it a try. Long story short, it turned out not too bad for a rookie. Now I'm hooked on woodworking and love making stuff. The cross-cut sled was a game-changer, love it. Thanks again and love your humour. You are an inspiration to me, to keep trying new things.

[@professorx45acp42]

I love you man. You are saving me so much money. My wife and I are in the process of planning to remodel our kitchen, however, we went, and please don't get upset, to Home Depot to purchase butcher block counter tops, flooring, tile and cabinets. I was blown away by the high prices and low quality that they offer. I am a tradesman and know that I can build it all myself, however, I have never built cabinets or counter tops before. After watching your videos I inventoried my tools and found that I have all I need to make my cabinets, shaker style doors and butcher block counter tops already. All I have to purchase is a DADO and a hidden hinge jig. In the end we will have a custom high quality kitchen remodel that will look like we spent two to three times as much but the savings will be in the work that we will be doing ourselves. I appreciate you sharing your craft with the world and by the way, you are funny as all get out. Thanks again.

[@photodog13]

Your K.I.S.S. Method for the top layer with the T-track is perfect! I’ve been putting off making my sled but your cuts make it easier than running a dado slot to fit the T-track. Going with a 1/2” base though to save a little weight and a slight more blade height. Thanks for the video.

[@paulio818]

Yeah this design is smart. Good idea about the 1/2" base to save on weight and height 👍

[@mariah2499]

So glad to read your reply. I’m working on one tomorrow (at least that’s the plan) and am using ½” birch too. I may use ¾ for the fence near my hands; front/back (there seems to be a debate).

[@Habu71]

I wish my real life shop was like the youtube shop you have where its magical and you tell me what we are building and there is magically gorgeous stocks of wood stacked and ready to go. lol. I dream man.

[@michaelklein496]

Love this book! kzbin.infoUgkxpCNxqmAkyjN6NPx1fyB7QiEFWyO5mUWL it is simply one-of-a-kind! I really love it, because karah explained all tools required to have the job done, not mentioning the fabulous diy pallets ideas. I'm pretty sure this will be a fresh start in my new endeavour. Amazon was great, they delivered on time. Thank you!

[@Naz_Vibes]

What size sled base did you with?

[@rickvervoort9536]

One of the better subscription's if you like comedy skits and woodworking knowledge.

[@halfbubbleout]

Easiest way to find a lost thing is buy a replacement. I usually end up parking the new one right next to the "lost" one!

[@randymcarn]

True story

[@treeorwh2]

I laugh because it is true.

[@xavirik4828]

Haha that happened with my old mitre guage

[@dgillespie13]

The most elegant 546 Pound cross cut sled ever made.

[@hellfire109]

That was a solid Lord of the Rings hobbit theme on the tin whistle, Jason. Nice sled build as well ;)

[@zachstanbery4060]

Came here to say the same thing!

[@mpshumake]

dude. you're doing a hell of a job. these are funny as hell. And super helpful. [robot voice] I am going to join bespoke post just because they are sponsoring you.

[@jferares]

Loving your channel! Thanks for the video. Think I'll go ahead and get one of these Katz Moses stops. :]

[@katzmosestools]

BoOom!

[@benjaminmckinney365]

Hey Jason that is the best cross-cut sled I've seen so far.

[@budtownsend7925]

Absolutely loved this video! Going to recreate your sled this week. Thus the first video of yours I have viewed - your instructions, camera work and banter are without equal! Thank you

[@paul6389]

Great video and idea! I appreciate your “humor” throughout! Idk what that says about me (or you, for that matter!) but it makes it fun AND entertaining.

[@thecaseybonham]

I wish the “crap” laying around my shop were that nice lol

[@williamfotiou7577]

Loving that Great Wall of Woodpecker! I’m envious 😊

[@MCmotorsports12]

I love how after he is done using the cross cut sled he just made for the entire video he finally adds the safety block after he is all done.

[@sandips5120]

That's the weirdest boat I've ever seen.

[@watcherofwatchers]

Don't put your hand there. Duh.

[@miguelcifuentes9390]

This the absolutely best table saw sled video tutorial, EvEr!

[@Wintersandman]

Would be curious how you handle crosscut sleds for a job site saw. That's all I have at the moment and I wish I had the outflow table/side table setup you have.

[@nobytes2]

There isn't a need for an outflow table. I had a dewalt job site saw with a sled and used that for years.

[@hillertj]

I made something like the sled in the video for the 8.25 inch DeWalt DWE7485 table saw. It's a lot smaller, about 24" x 24", but so far it works great. Getting the width of the runners perfect and leaving a little space depth-wise, so the slots don't bottom out, is pretty important. Zero wobble.

[@nicknola9670]

The fact you played LOTRs music on the flute. You are no.1 on youtube!

[@herpderp9430]

This is my favorite woodworking channel on the internet.

[@Im4realtryme]

Best video for cross cut sled I've seen, will definitely be making one.

[@justa_grandpa]

Nice build overall. Use the extruded aluminum as the main back fence and secure from the bottom of the sled. Add sacrificial fences to the front using T-nuts in the channels and replace as necessary for thin/regular/dado kerfs. The stop extends out so it is still usable. Notch out the extruded aluminum 1" and that removes the potential trigger on SawStop saws.

[@ltbuck1]

Enjoy the show, put a big smile on my face thank you! Look forward to building my sled LOL that you have just built. Can’t wait to see the next project

[@just__dave]

I was so excited to see a new notification thinking “BOAT!!!!” But you know what? A table saw sled will do just fine. 😉

[@nathantripp9134]

I'm so thankful I found this channel. It's a wonderful mix of comedy and information, and it always makes me smile.

[@djbachelor]

Terrific! I need to build a new sled and decided to browse for inspiration; knew I'd get just what I need with some Bourbon! My only question is about using 3/4" vs 1/2" ply, curious what the community thinks of the tradeoff. Giving up 1.5" of cut depth on a 10" saw seems like a LOT. Any down-sides to going with 1/2" ply?

[@michaelcoughlin8238]

This is what was thinking. That finished product was super thick.

[@matthewcluskey7659]

Happy customer here. I purchased the plans. A bit of constructive criticism: I watched the video before purchasing the plans and didn't even notice it, but in the plans you refer to the front and back fences in a way that is backwards to me. The front fence to me would be the portion that enters the blade first. In my mind I'm standing at the rear of the saw. The blade spins towards me, which in my mind means the back or rear fence is the one closest to me. Fantastic plans and amazing videos - just felt it was worth mentioning pointing out. Kudos!

[@MajykOyster666]

That's a really thick crosscut sled. And I thought my 18mm (~3/4 inch) one was heavy. :D

[@SidewinderINC]

You popped up on my suggested feeds after I've been watching WWMM and WWW for a while. Great Advice, Great Humour, Great Beard, Great Tunes. *subscribed*

[@msmith2961]

Awesome build and entertaining as always. With mine, I bored out a hole in my workbench so I could drop in a piece of ~22mm dowel to act as an end stop. That way I can't push the blade through the back of the 'hand reminder' block if I have accidentally used it as a handle..

[@arth.4196]

Bearded man has done it again. Shown me an easier way. I have learned so much. May by I can visit the shop when this pandemic is over........

[@Dogo24h]

Very helpful! Thanks for sharing!

[@nealsalsgiver5163]

Your ode to The Shire flute music deserved an applause. Loving your videos. Small scale woodworker from the PNW and have learned a great deal from you. Keep them coming. Cheers!

[@robm9772]

I’m literally in the middle of building a cross cut sled. Now I wish I had waited another 24 hours.

[@SR-te2db]

Why, were you gonna follow this guide of making a sled with shit no one has lying around? Lol. If anyone knows a channel for the regular person, without festools in their shop, someone link me.

[@builtbyjudas1471]

@@SR-te2db izzy swan every day ever

[@davidcardosophotography]

@@SR-te2db woodworkingformeremortals

[@markranger4871]

@@SR-te2db I'm managing just fine without the specialty tools. End result much the same. Simple sled , keep it simple stu**d ;-)

[@JamStph]

Listening to the tune you were playing, I feel better about my LOTR dorkness, I am glad that I am not the only one out there.

[@nekelly123]

I'd recommend the 5 cut method for perfect squareness.

[@Steadfast_Faith]

Why? If it's perfectly square the way he did it, why do the 5 cut method?

[@nekelly123]

@@Steadfast_Faith 1) checking with a square is prone to error and relies on the accuracy (or not) of the square 2) putting shims behind the fence could cause the fence to bend causing innacuracy.

[@dsweetman716]

By far the coolest cross-cut sled I've seen yet. This is the one that I am going to build. Thanks for sharing. Great video.

[@matthewharper9615]

5 cut method for squaring a fence, easy to do, more accurate

[@Steadfast_Faith]

More accurate than a perfectly square cut the way he did it?

[@matthewharper9615]

@@Steadfast_Faith Yes, but it requires math skilz

[@chm1701]

Great video. I’ll definitely keep this in mind for when I (eventually) get a table saw.

[@eddee2974]

when you use your dado set won't it cut a wide groove through your aluminum fence?

[@robs9122]

Without a doubt best sled I have seen. I like the aluminum back more.

[@lokidjb]

Nice, looks great... but instead of stacking up additional plywood inside I would have sunk the T-tracks and the zero clearance part in the base plate with a router, so I would not lose too much sawblade hight.

[@scottburkhardt6859]

But then he loses the dado adjustment capabilities he wanted, right?

[@lokidjb]

@@scottburkhardt6859 hmmm .... don't think so ... why?

[@darrylbhopkins]

You don’t lose too much height. If you want to dado a t-track slot then you need 3/4” plywood. But with the 2-layer model you can use 1/2” plywood, for a total height of 1”. So this 2-layer sled is only 1/4” taller than a single layer 3/4” sled.

[@McLabskovs]

Here is Mac Allan from Denmark ... Thanks for your way of being ,,, and a happy weekend to you

[@XFBO]

It'd be interesting to see how straight you think it is by doing the 5 cut test!!! ;)

[@cherifowler137]

Very intuitive, super photography, and I love your comments!!

[@chipgillespie6538]

It's gotten to the point where I'll watch other woodworkers' videos and as they're assembling their pieces, I hear YOUR voice say "Aaaaand, we're just gonna hook 'em together with..." It's crazy. You're in my head, dude...

[@JamesWilliams-en3os]

Okay, I have to say this, and don’t let it go to your head... but this is possibly the best crosscut sled concept I’ve seen. I have a long and passionate love-hate relationship with my crosscut sleds. I’ve built and scrapped several of the things over the years, and with use have always found flaws that make me crazy. This sled addresses every issue I’ve had. And yes, JKM’s stop is amazing.

[@abdullaalsaffar8460]

I am waiting for the boat bro ...! However , nice vedio as usual 🤨

[@leyderness3553]

At least you found the T track the last place you looked!!!!! I sure could use one of those. NICE WORK.

[@jcarletto27]

JKM is such a swell dude

[@katzmosestools]

I heard he's a mouth breather

[@reymalaret9664]

Great, I have tried twice to make one. I think this time I'll try yours, thank you for the easy going instructions.

[@woodenplant7202]

You and Jonathan Katz-Moses should do a video together! Also nice sled!

[@katzmosestools]

Agreed!

[@scottsasanecki4106]

I have been binge watching your videos for two days now. Very informative info plus you are hilarious. You look almost identical to a buddy of mine!!!

[@akbychoice]

Nice build. Curious how much depth of cut you have with having 1-1/2” thick crosscut sled? Just an FYI dado stack and that aluminum might not turn out well.

[@twotwentyseven]

Lots of good ideas here! Especially the swappable insert. I'd only want to drop some of the weight. I've had extra large sleds with big cut outs on the base and aluminum tube instead of the 1.5" ply wood ends.

[@MrLower]

I am assuming you wouldn't want to do the aluminum backer with a SawStop... BUT I bet for the SawStop users out there, we could always gap the fence an inch or so on either side of the blade with some wood Also, do you find that by adding the secondary base with the T-Track that your blade doesn't reach as high? Or do you mostly just use the sled for cutting thinner material?

[@TomHoppe]

I was thinking that same thing, but I'm realizing instead of that extruded Al, we could just use a second piece of plywood with the t-track on top

[@williamtaylor1011]

@@TomHoppe It didn't do me any good. Bangx2 ($130)

[@ardlehatley8253]

i have watched other wood workers and you do the best

[@kevinjohnson2656]

more BOAT now!

[@lionelroy4323]

I know what I'll be making. Awesome addition to my tools. Thanks

[@KyleLibersat]

The "hump" in the fence serves two purposes: 1. Strength where the thru cut is and 2. Keep your fingers away from the blade. I put a hump on the front fence too, but might not be very functional with the stop you are using. I always size the hump so that my fingertips can't reach the blade.

[@JJ-fd2ob]

incredible stuff here....GOLD..........thanks for sharing this. I think the only thing i'd change is adding threaded recessed screws for easy attachment and removal and reattachment of the blade/dado cover piece.

[@markwaple3186]

Cool sled!! I would love to have all that "Crap" laying around. :-)

[@johnharrison8807]

Best Crosscut sled ever. Going to make one just like it.

[@bentcountershaft]

That's the weirdest boat I've ever seen.

[@thomasdunham5427]

hollywood is looking for this guy!!!!

[@Drew-de7ey]

That sled would take up half the depth of cut capacity on a 10" saw. Nice rig otherwise.

[@stephenackley-ortiz2244]

I was thinking the same thing. Love the design otherwise.

[@charlieodom9107]

How do we fix that? I love the idea, but I need one a lot thinner. If you cut dados into the plywood for the T-track, then it will make the whole thing flimsy. Maybe make one out of metal to keep it strong but thin? Maybe add metal bracing to wood to strengthen it in places?

[@urwholefamilydied]

@@charlieodom9107 Ya, I noticed how thick it was too by the end. I think if you were to build it with ALL materials being half as thick... by the time everything was screwed and glued it would be plenty sturdy.

[@charlieodom9107]

@@urwholefamilydied a 3/4" sled would give me 2.5" or so cut depth, which I believe is more than enough for my little saw. I'm building a new tablesaw out of a cheap Ryobi plastic portable saw right now. The plastic one was too flimsy, but there was nothing wrong with the motor or mechanical bits. My top will be 3/4", with further stiffening under the area where T-Track will be placed. I'm still working on mounting the motor to the front of the new cabinet, but I believe I'll have just over 3" of cut depth once finished.

[@dumbdumber1885]

maybe make the first layer out of 1/4" instead of 1/2" that would get you anothter 1/4" lol. or maybe the 2nd layer could be 3/8" then you got a total savings of 1/2"... that otta be enough thinness for anyone lol. jk :)

[@peterconnolly2724]

This is officially now my favorite Woodworking channel...

[@coehenstackle1889]

I may or may not have watched this video instead of writing my essay that's due tommorrow

[@carlatkins83]

Lol man great vid. Just came across this and checked it out. I love the teaching and the humor. I definitely subscribed. Be blessed

[@1975oldschool]

Liked the video.... although a full sheet of ply isn’t “stuff” laying around lol

[@matteout_woodworking]

I have a full sheet of ply laying around the shop. I always buy more material than I need when building stuff.

[@1975oldschool]

@@matteout_woodworking yes. exception to everything.

[@tedcox3586]

@@matteout_woodworking really? 3/4 Birch plywood? What did you have that left over from?

[@matteout_woodworking]

@@tedcox3586 I'm a professional woodworker. I will use it on something so buying two or three extra pieces when I build cabinets isn't a big deal for me. The thing is that the time I spend going back to the plywood store cost more than buying a few extra. The same with lumber. I have like 2000 board feet of lumber in my shop minimum. Ranging from oak to pine. If I get commissioned to do a job I have the lumber to do it. It's seasoned in my shop and ready to start production.

[@tufankilinc636]

Dig this. I will build it the same. Thanks for not over-engineering it.

[@davemacgyver573]

I think I would have used 1/4 or 3/8 plywood on the bottom. The problem with using the 3/4 plywood, is you have reduced your depth of cutting ability. The front and rear faces would have held it straight and flat....as would have the thicker plywood added to the inside. That's my only constructive criticism to add.

[@herbb8412]

Not to mention the 160# weight 😆

[@cliffsmith8755]

Sweet sled. Nice when the "crap" in your shop includes a $70 sheet of plywood. I should be so lucky. Now I know what to do with that left over T-track. Thanks man.

[@sandips5120]

iMPRESSIVE EXCEPT IT WOULD TAKE 3 MEN AND A BOY TO LIFT THE DAMNED THING lol

[@rexseven6907]

And it's so thick you can only cut 3 sheets of paper on it.

[@ChipWooder]

The LOTR music being played was a nice touch, huge props.

[@robertg3921]

You can not do that Im here for the BOAT triggered

[@josepheustaquio5544]

i am super digging this idea for a new sled... Time to go build this TOMORROW. Love it. Thanks again!

[@surfinturfer]

For a really simply and completely precise way to check for square, I recommend the five-side-cut method. Take a board about 12" on each side. Cut an inch off one side. Put that side against the fence, repeat; repeat again, and repeat again, until all four sides have been cut. THEN slide the board over and make a 1" cut and check the width of the 1" board with calipers. To see it done, go to "5 Cuts to a "Perfect" Cross-cut Sled" at kzbin.info/www/bejne/i5OqXqFjYrF5nbM.

[@jimweisgram9185]

For an even better and faster method I suggest using a dial indicator and an accurate 90 degree reference square, the longer the better. Clamp the square to your fence, set up the dial indicator with a magmount base near the tip of your reference square such that the tip of the dial indicator rides on the edge of the square. Zero the indicator to 0. Push the sled forward and backward. Once you have the fence showing very little deflection, you are golden. I shoot for 0-0.002 thou. After that you can lock down your test cuts and use the 5 cut method, if you like. Alternatively, you might try the Rob Cosman method of attaching the fence. He takes the base piece and cuts a rabbit along the edge where the fence goes. Then when he attaches the fence in the rabbit, it is already square. If it isn't, your saw or it's fence needs tuning up.

[@marcelscott6490]

That does look like an awesome sled. Nice work. I have watched about 100 videos on how to make one, this video is the best. Thanks.

[@BeBreezy-zg8fl]

80% of my time spent during projects is searching my garage

[@darrenbuckney6683]

Nice man. my next project well done love ya work.

[@Couldnt-think-of-a-clever-name]

I wanted to make a new sled when I started watching this vid.....for some reason I ended up watching lord of the rings...weird

[@carlosvalentine4939]

That looks very heavy 👍👍

[@danbarrett6113]

Uh dont run the dado stack through the aluminum........ Im just sayin...

[@kbliss24]

I was wondering about that myself?

[@Bongomaniak62]

Been watching your videos for a while and love them. Love the comedy as well 🤣🤣

[@bryanklaproth6020]

Just cut the aluminum on someone else’s saw

[@4149dwiley]

Very nice project. So much better than the typical sled I have seen constructed in other videos. Especially like the removable dado section.

[@mattberg916]

Check out AVE. The hierarchy of materials. Carbide cuts ALL, except for the stuff that us normal people can't afford

[@mickprince8529]

This looks like Kings Fine Woodworking’s crosscut sled. Pretty nice, I am going to give it a shot.

[@johngorman4052]

AWESOME, MAN!!! Great Skills, beautiful job and brilliant finish.

[@lionelroy4323]

this is gonna be so useful to make square cuts. Like the idea of the aluminum pieces to incorporate hold downs. Oh the joy :)

[@lauramarshall6376]

I built almost this exact cross-cut sled. Thanks for the idea of using the extruded aluminum. And ... it was as easy as you said to shim it. I got it to within 1/1000 inch to square! And, putting the t-track on the sled was also a piece of cake. You are a genius!.