Table Saw CROSS CUT SLED w/ Stop Block & DUST COLLECTION // How To Make

Learn how to build a table saw cross cut sled, complete with a t-track stop block and hold downs plus a custom DUST COLLECTION hood! A cross-cut sled is one of the ultimate table saw jigs, allowing you to safely cut long parts to length. Purchase the crosscut sled plans here : bit.ly/crosscutplans
5 Cut Method Calculator : www.windridgewoodcrafts.com/t...
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📦 Materials Used On The Crosscut Sled (affiliate):
🔹 2 x 24”x30” ¾” Baltic Birch Plywood : www.rockler.com/3-4-baltic-bi...
🔹 Double T-Track : www.rockler.com/double-t-trac...
🔹 2 x Universal T-Track, 2 ft : www.rockler.com/universal-t-t...
🔹 2 x Miter Bar, 24” : www.rockler.com/rockler-18-24...
🔹 Tape Measure Insert Kit : www.rockler.com/t-track-tape-...
🛥 TotalBoat Halycon Clear : amzn.to/2ziBSnN
🛥 TotalBoat Elixir Paint : amzn.to/2XlNgIt
Stop Block : bit.ly/KatzMosesDovetailJig
Wood Glue : amzn.to/3hXuy1Y
#6 Screws : amzn.to/2XezgjM
4 ¾” Screws : amzn.to/33bXoXZ
¼” Acrylic : amzn.to/39J2OuV
Acrylic Cement : amzn.to/2Pf5SFQ
🛠 Tools Used On The The Crosscut Sled (affiliate):
Table Saw : amzn.to/2WrrNMm
Push Stick : amzn.to/2XIvgFq
Router Table : • How to make a ROUTER T...
Calipers : amzn.to/3g02Hxd
Countersink Bit : amzn.to/3eX5GFE
Magnetic Screw Holder (for my impact driver) : amzn.to/2xGYPwD
Cordless Drill : amzn.to/2wOFM2S
Dado Stack : amzn.to/3fliYf6
Sjobergs Workbench : amzn.to/2s4mffP
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SCRIPT:
I started the crosscut sled build by ripping a piece of ¾” Baltic Birch plywood into strips at the table saw. These pieces would make up the front and back fences on the sled, and to help beef up these fences, I glued two of the strips together to form 1 ½” thick fences.
Also, in case you’re interested in building one of these sleds for yourself, I do have plans available that include all of the specific dimensions I used, and I’ll link to those in the cards and in the video description below.
After the glue had a chance to dry, I took the fence blanks out of the clamps and then squared them up at the table saw, scraping off any excess glue squeeze out from one edge before doing so.
Once I had the edges cleaned up, I first cut the back fence to length by cutting one of my fence blanks roughly in half, and this was again because I was creating fences for two sleds.
I could then clean up the ends of the front fence, which I kept as long as possible, removing just enough material to square things up.
While I had my stop block set to length for the front fence, I also went ahead and cut the double t-track I’d be using on top of the front fence to length as well. I had to cut off a bit from one end of the double t-track to make sure the screw locations worked out for my fence size, but this aluminum t-track cut easily with my miter saw.
Next, I could get a slot cut into the top edge of the front fence to house the bottom portion of the double t-track. This piece actually helps to keep the fence straight, so I tried to keep the slot nice and snug, while also making sure the t-track was just shy of the face of the fence so it didn’t interfere.
Before screwing on the t-track, I went ahead and chamfered the edges of the fence at the router table, adding a heavy chamfer to the front edge of the fence. This chamfered area will give a place for sawdust to pile up without affecting the accuracy of the fence.

[@craftedworkshop]

Thanks for watching y'all, hopefully you enjoyed this one! *Purchase the crosscut sled plans here : **bit.ly/crosscutplans*

[@TomHoppe]

What are the dimensions of the sled you built for your job site saw? I have the same job site saw you have as my main sled, and I think the 24x30" would be a bit too big for it, but the rest of this design is sooooooo good.

[@FrankTheTank417]

@Crafted Workshop be are when applying too much pressure when rolling down the edges of laminate on your wood. It’s very easy to crack the laminate then you are stuck pulling it off with lacquer thinner. Also if you use laminate often you might want to look into purchasing a Spray gun for you laminate glue. It cuts my time down drastically from the old roll on method. Great videos. Also they make specific router bits to use for laminate.

[@easyRider728]

Dude, I love how you just got into it and didn't spend 5 minutes talking about something we all already know about. Appreciate that

[@AngieWilliamsDesigns]

I love my current cross cut sled. But adding dust collection is definitely the way to go. Great build!

[@joshuac1364]

Awesome build. I like the dust shield more than I thought I would.

[@SpencleyDesignCo]

Wicked build! You really got me with that dust collection add on! Keep it up 👍

[@FredMcIntyre]

Awesome work Johnny, that's a really cool sled! 😃👍🏻👊🏻

[@WCW4469]

Nicely done, great looking sled.

[@rimaggio]

This has to be the mother of all overkills!

[@Valtrach]

Top quality video. Thank you for your time and work.

[@Joshua-tq4jg]

Awesome video! I love that dust cover!

[@derekjarman1638]

Nice! The laminate gives it a nice finished look instead of just ply👍👍

[@capti443]

Nice build! .... I built one very similar to yours back in the mid 1990’s. I stayed away from plexiglass and acrylic because they can fracture; instead, I used 1/4” Lexan / polycarbonate which WILL NOT shatter if hit by an offcut. I attached it to light-gauge aluminum angle with pop rivets. Dust collection is through a 2 1/2” adapter similar to yours, available at Rockler, Woodcraft, and other places. While I replaced parts as they got worn from use, the sled is still in service and dead-accurate. One thought: to get the fence dead flat which is hugely important, I glued it up atop the infeed table of my 8” jointer - which is the flattest reference surface I have. Lastly, dust collection is immensely improved with adjustable side shields that can be lowered down as needed. This is especially effective when trimming a light cut from the end of a board that would otherwise throw dust all over the place.

[@davidnleeh4]

Thank you for posting this video and ESPECIALLY the link to the online 5 Cut Calculator!!!!!

[@rkerby6375]

Well done! Thank you for sharing.

[@mchtzn]

Best one that I see so far! Congrats, you are good!

[@diymakers7901]

Thank you so much for this video this helped me so much with my cross cut sled build

[@MCsCreations]

Pretty fantastic work, dude! It really looks fantastic! 😃 Stay safe there with your family! 🖖😊

[@keirfarnum6811]

Nice work! Thanks for sharing.

[@MrJauxT]

Awesome sled man. I've been looking to make my own but I'm glad I waited. Definitely giving this a try... pre-order done! Keep up the great vids!

[@craftedworkshop]

Awesome! Thank you!

[@nordyfamily]

Keep up the great work!

[@SchysCraftCo.]

Very nice up there for ur shop make on my friend keep up the great work & craftsmanship

[@guitarckyplayer6112]

woah, never seen a JET miter saw. Looks awesome, and I love the blade. Also, great work on the build, great videos!

[@bjharlow3598]

One of the best sleds I’ve seen. Nice job!

[@craftedworkshop]

Glad you like it!

[@Warkive]

I wander to and from a lot of woodworking channels, subscribing to only a select few so my feed doesn't overload. I've watched quite a few of your videos prior to this but that dustguard for your miter hood is the reason I clicked subscribe. Fantastic idea, thanks.

[@markpalmer3071]

I think that's the first one I've seen with a dust hood, what a cool idea...

[@craftedworkshop]

Thanks!

[@sapelesteve]

Great work Johnny! That's quite the crosscut sled & one of the best that I have seen on YT! 👍👍😉😉

[@craftedworkshop]

Thanks 👍

[@adamdearing918]

Excellently done. Both build and video! I have just built a new crosscut sled and I’m going to use your ideas about the dust hood. I really like that! Thanks very much for sharing your skills and ideas. 👍👏👏 You just got a new subscriber too! 😎

[@jeffreypursley1914]

I had the same problem with the Rockler Tape Measure Inert Kit being too tight a fit in the track. Spent way too much time using a carbide scraper on all the edges. Finally got it to go in and still be a very tight fit, not sure that I will utilize it in the future for any other builds. Love the dust hood idea, something I would really like to add to my saw to help with the dust collection. Thank you for posting!

[@brianwalker260]

That's the cleanest approach to dust collection I've seen on a sled. I've been meaning to remake my asked after the fence warped, so maybe I'll add that in the process.

[@craftedworkshop]

Thanks! I definitely think it's a great addition. I'm actually planning to whip up a version 3.0 using the CNC and some rabbet joints so it'll be even cleaner.

[@g040700]

@@craftedworkshop did d u make that version?

[@Airn5475]

Good design! Best I’ve seen. I loved your dust shield. I wonder if it would work to have a hinge on the back and then it could swing up and down adjust to the material thickness. Even stand up straight out of the way?? 🤔

[@Andy.H.H.]

This is the first video I've seen of yours and I really liked it! The 1 comment I have is about the dust collection hood. I would add a hinge at the back of the hood and maybe some kind of simple 90 degree turn hold down to the front to make it easier when clamping/unclamping the wood pieces to the sled. Nice job!

[@lotharfunke8749]

Great video 👍

[@BradM1970]

sweet sled man

[@DsHardWoodCreations]

Great vid!!! Well done

[@craftedworkshop]

Thanks!

[@LogHouseFarm]

That looks like a lot of work, but ends up being a very nice sled - thanks for the video.

[@mikesparks3398]

good stuff!

[@whiskeylung]

This guys sled costs more than my table saw.

[@oliverdelica2289]

Haha fr

[@brianlevine249]

@@oliverdelica2289 I know right! All those aluminum T tracks stops dust collection. Lol

[@waveoflight]

Why is the $30.00/qt red Paint so important on this build, as opposed to any other red paint?

[@erichdelossantos4701]

@@waveoflight maybe because its what he had already instead of buying paint?

[@PhilBuildsThis]

@@waveoflight $pon$or$hip monies?

[@juanrusso2423]

Excelente proyecto y ejecución!!! Te felicito y mil gracias por compartirlo. Saludos cordiales desde Morón, Pcia de Buenos Aires, Argentina

[@ByrdAnthony33]

Def going to give this a shot! Love your videos, simple and to the point! What camera setup do you use?

[@katzmosestools]

Great sled JB! I love the use of laminate and the dust guard. Even with safety glasses I always kind of stand cautiously out of the path of the blade while using my sled. Thanks for the shout out. Great build!

[@j1ones11282]

Viewing port for tapes will be stop block 3.0 🙂

[@judas587]

Wow. So cool Johnny brooke I love your contents a ton . I wish you were my friend but I are in the 🇺🇸 us and I am in 🇲🇺 Mauritius. But that doesn't matter because you are my friend on KZbin 😊👍. Hope to see your next project . Watching ya all the way from 🇲🇺Mauritius . Lots of love

[@Zachw172]

Aww

[@Zachw172]

I have found where you live! en.m.wikipedia.org/wiki/Mauritius

[@syedhasan6548]

Very Nice 👍

[@brianholm4201]

How do you get the plans for your sled

[@eliotmays]

Looks great. Two points to help with dust collection. 1) If your port was mounted towards the front of the hood, it would likely capture more dust. You could mount it on the side to maintain visibility. 2) Mount your red guard block all the way to the table and it will keep dust from blowing out at you when pushing it through.

[@craftedworkshop]

Good call!

[@tvkimslifetv8609]

Best crosscut sled ever! One question is what's difference between using normal cross cut sled( unlike yours, the one has no safety guard and dust collector) and using miter saw? Isn't miter saw easier and safer?

[@dmosbbq366]

For the dust hood, you could also set it to one universal height and then add bristled door sweeps to flush it up with the sled

[@DixyPro1]

Good job. I was able to make one automatic that works on 12 volt

[@glenpaul3606]

Very nice crosscut sled. I was hoping you would have built in extensions to the front fence. One to allow for a Dado blade and the other to extend the fence length to accommodate longer pieces that need to be cut. I plan on building a crosscut sled and would like to incorporate adjustable fence extensions along with some of the features you added to yours.

[@shahzkhanaz2655]

good teach....

[@FranksDIY]

Looks awesome. I really like the plexiglass dust cover . Hope to see some awesome builds using that sled in the future

[@timderks5960]

Dust extraction on a crosscut sled is a really nice idea, I don't think I've seen that before. Since you're not very likely to use the rear half of the crosscut sled very often, how about adding some CNC-like brushes to the acrylic there? That way it should improve dust extraction in the front even more, and if you have a larger piece to cut some day, it still works fine. I personally would be hesitant to add brushes along the entire length, both for ease of use and safety reasons.

[@denverrenfro2933]

Nice job! Like that you have all the pieces you used from Rockler with links. Do you think Rockler would work with you to create a package buy for all the pieces? Maybe bundle it with your plans?

[@AGTDesigns]

Man..this is the most over-engineered sled I've seen, and it's most likely the best one as well! Congratulations on getting really awesome ideas on something that has been build a thousand times on YT, it is definitely difficult to be original in these cases and you've mastered it. Also, kudos on supporting JKM stop block, it's great to see makers supporting other makers. :) My only question is why have you placed the dust port so far back? When the blade is near the fence the dust port is way back...probably you have really great suction from your dust collection and it doesn't make a difference, but I'm used to adapt my dust collection to shop-vac suction, which is why this came to my mind. :) Cheers!!!

[@WalterFieldingJr]

I’d think the reason is that having the dust port above the blade or forward of it would obscure what you are cutting. Also I think the hose would get in the road if it was further forward too. Just a guess.

[@acopley8705]

That miter saw blade is so incredibly shiny! Do you ever use that as a mirror to check your hair before filming?

[@ldb8435]

just thinking the same thing, is it chrome plated?

[@marcusretaken72]

Great. Now I have to build another sled LOL

[@WoodWorkLIFE]

The woosh when you removed the feeler gauge made me laugh.

[@ramakreatif3944]

W O W. . . . Good 👍👍👍👍👌

[@JoeGilpin3837]

Looks great, you might want to reconsider to Polycarbonate or "lexan" instead, a lot stronger, and wont blow up in 1000 shards if something ever happens someday. Like the acrylic will.

[@StraightWhiskey9]

The most gucci crosscut sled ever made. I like it

[@lilmax38]

Working on some projects with 1/4” plexiglass with my daughter we clamped down one side/end with a board. I don’t remember exact measurements, let’s say 5” then with it clamped we heated it with a heat gun, never leaving it in one place, constantly moving it back & forth & very very slowly with patience bent it to a perfect 90° angle. Looked really sweet & came out very nice. Just throwing that tip out for anyone maybe wanting to make one solid piece of plexiglass. 👍

[@joedance14]

Very nice work! Q: What overarm & blade guard is on your table saw?

[@francescosaccaggi6427]

Which feeler gage did you use? I was looking into getting one but there are too many options.

[@BigmoRivera]

Nice Job 👍 Hey Is That A Mirror Blade 😀 Is That The Infinity Blade

[@kevinhoppenworth6708]

Your drill press chuck is wabbling needs to be seated into the shaft a bit tighter. Love the sled. I had the same wabble on my drill press.

[@proxymine2674]

Could you put brush like material along the dust collector edges to help contain more of the dust while also letting the material slide in from the sides?

[@craftedworkshop]

I was actually thinking of doing that, should work great!

[@rosswells4090]

What kind of saw blade do you use in your Inter saw? That thing is like a mirror.

[@martys356]

When I laminate a project I use dowel rods to keep the laminate from sticking to the wood as I line it up. When cutting laminate I have a piece of ¼" plywood that fits around the rip fence and lays flat to the table so the laminate won't slip under the fence and it's a zero clearance.

[@ymx777]

Hello. Is a throat plate required when using a sled like yours? Im thinking dust collection may be a little better without it?

[@TheGc66]

Very innovative, i like the implementation of the bladed double track up top and the dust shield is pretty dang genius! like the other commenter tho, prolly need to replace that sometime down the road with lexan, cause i see you needing to wipe/clean out the dust periodically, and that'll scratch regular plexiglass in time and most likely impede your visibility in time. VERY Nice Sled overall! BTW, Ron Burgundy called and wants his inflection back. "...News at 6"

[@craftedworkshop]

Thanks a lot! I honestly don't use the sled as much as I thought but it is very handy.

[@280nosler]

How do you get & keep your mitre saw blade mirror-like?

[@timrothgeb416]

You may want to bend the plexi next time instead of bonding 3 pieces. It makes it stiffer and you can use thinner material. Plus it stays clear.

[@ericdeguilo1181]

sorry if you've answered this before... what blade do you have on your miter saw? i've never seen anything so shiny in my life, including my bathroom mirror

[@goemaerefabian6998]

SUPERBE PLATEAU

[@fosterelli6455]

Very nice build man! I'm totally adding dust collection to my sled now! I think I've inhaled a few pounds of walnut in the past couple of weeks. By the way, what saw blade are you using on your table saw? I have the OEM SawStop on my PCS and I'm starting to look for a higher end one for minimizing tear out.

[@craftedworkshop]

Go for it! And that is actually just a SawStop blade, nothing fancy. I think the Forrest Woodworker II is the best one out there but mine needs to be cleaned : amzn.to/3hUWNya

[@edmundhayes7982]

Not sure how you attached the runners. You said bolt with lock washer. Was the runner threaded?

[@soniarosado5971]

What kind of screws should I use for wood fence?

[@derekw40]

What miter saw blade do you have ? I’ve never seen one with a mirror finish.

[@darthbari]

A jet

[@garagewizzard]

Have you consider using polycarbonate ( I think it's called Lexan in the US) plastic instead of plexiglass? plexiglass shatters on impact. You could also bend it in one piece using a line heater into a U shaped channel to remove the need for adhesives. Otherwise, very professional video, Nice!

[@GotCamel]

Yooooooo! What is that blade you have on your miter saw?!?!

[@vincentmerola5842]

Hey I’m a new woodworker having a hard time figuring out what type and screws to use to secure the rock t-track runners and secure them. thanks

[@vincentmerola5842]

And more importantly the rockler aluminum miter bars trying to figure out the screws to use to secure them without them sticking out proud and the Miter slots

[@craftedworkshop]

Really just depends on the thickness of what you’re mounting it to, I typically use small drawer slide screws.

[@russ5234101]

I just subscribed to this guy and immediately realized he’s gonna cost me a lot of money 🙄

[@isaacocasio3165]

If I wanted to just buy one from you, what would that look like?

[@alejomoreno6524]

Does anyone have a recommendation for the size of the crosscut sled compared to the size of the table saw top? Most sled plans I have seen are for contractor sized tables (like on this video), but curious what a good size would be for a sawstop job site saw.

[@SharpestBulbs]

If you have a contractor saw check that your blade is sufficiently far back from the front edge of the saw (the side you stand on). What most of these videos don't tell you is that a crosscut sled doesn't work on a small contractor saw unless it's had some sort of infeed table built around it. The reason is that the runners will have quite a bit of slop until both are inserted at least 1/3 or the way. To answer your first question, assuming you built an infeed for your contractor/portable table saw or that the distance to blade is deep enough, you should make it as big as you want as long as it's even on each side. Just think about the material you'll most likely be cutting. If you're crosscutting 8' 2x4s then you'll probably want it to be at least 4' wide, etc.

[@martinsmith6011]

Like the sled bud, on the two ends where you said you where going to use spacer's to lift on thicker material, just a suggestion what about two springs instead. Love the build. Cookie UK

[@alangardiner872]

i would be interested to see, if...battering that top insert ito the top T track, ruined your calibration of the rear fence??? it would have been good to see you do another 5 cut test after the hammering......

[@marciaconnor8246]

I can I get the file for the dust hose connection? I don't know how to use sketchup but my son-in-law said he'd print if for me if you give me the file.

[@dgramsz2146]

Do you have a link for the 5 cut calculator?

[@craftedworkshop]

Forgot to link it, here you go: www.windridgewoodcrafts.com/topics/five_cut/

[@dgramsz2146]

Thank you

[@ronin2963]

Everyone loves Rockler until they see the price

[@slightlycrookedworkshop]

Their price is better than those red tools made by a company named after a bird.

[@ronin2963]

@@slightlycrookedworkshop lol, you say that it is an accomplishment 😉

[@slightlycrookedworkshop]

@@ronin2963 I guess it's because I don't think Rockler is overpriced.

[@dhm7815]

What is"laminate"?

[@dofidopes7080]

Early my dude

[@anyalpine]

All those tools and that’s the largest square you have?

[@BC5391]

I like the shield, if ever make another, plexiglass is easy to bend so you will not have joints. It just takes heat from a heat gun, bend using pressure with scrap wood

[@craftedworkshop]

Good idea, I'll have to try that in the future!

[@austinbeetson6178]

Fusion 360?

[@alangardiner872]

how much do the plans cost??

[@brianewhiteguy]

Great job! Here's what I want to know: which kidney did you need to sell to get Plexiglas during a global pandemic?? :)

[@lukafilm]

But.. but... You didn't say: "Hello everybody I'm Johnny Brook!" How do I know you are Johnny Brook and not someone else???

[@rolly5457]

If cost wasn't a factor why would you make your own sled compared to getting the SawStop sliding crosscut table?

[@darthbari]

It fun to build your own

[@davidthompsen464]

Dude! Do me a favor and go do the "5 cut" one more time; I bet you're off .037 now!!

[@dougieyoung6536]

👍👏👏👏😃🏴󠁧󠁢󠁳󠁣󠁴󠁿

[@thatguythatdoesstuff7448]

A bit of rubbing alcohol on the plastic and a few drops on the aluminum and the plastic should slip right in.

[@dscritter614]

Makes my sled look like a 5 yr old made it.....on a bad day.