Is a crosscut sled worth it?

A crosscut sled is an indispensable woodworking accessory for any hobbyist or professional woodworker. But is it really worth investing in? In this article, we’ll examine the pros and cons of crosscut sleds to help you decide if purchasing one is the right move for your workshop.

What is a Crosscut Sled?

A crosscut sled is a guided jig that rides in the miter slot of a table saw. It allows you to crosscut boards and materials safely, accurately and repetitively at precise 90 degree or angled cuts.

The sled consists of a flat plywood base that sits in the miter slot and extends outwards, with a fence attached to the base at a perfect 90 degree angle. The fence runs parallel to the saw blade, guiding the wood at the desired width as you push the sled through the blade. The base has a center channel that allows the spinning blade to cut through the wood unobstructed.

The Benefits of Using a Crosscut Sled

Here are some of the biggest advantages of using a crosscut sled for table saw tasks:

Precise and consistent cuts

The sled guides the wood at an exact 90 degree or angled cut every time. This prevents tear out splintering and ensures precision. The fence ensures straight cuts without any skew or blade wandering.

Safer to use

With a crosscut sled, your hands stay far away from the spinning saw blade. You don’t have to use the miter gauge and get your fingers close to the danger zone. It reduces kickback risks significantly.

Versatile

A crosscut sled can handle a variety of wood widths and lengths. Short and narrow pieces as well as long planks can be cut safely and accurately. The sled offers stable support for the workpiece.

Cleaner cuts

The sled elevates the wood off the table for smoother underside cuts. The wood doesn’t drag across the metal surface, preventing burn marks and tear out.

Increased accuracy

The fixed fence guarantees straight cuts at the desired width every time. Measurements are perfectly precise down to 1/16ths of an inch.

Faster workflow

After initial setup, cutting multiple pieces is quick, simple and efficient with a sled. No need for constant remeasuring and adjustments.

Make angled and mitre cuts

Stopped cuts, compound miters and repetitive angled cuts can be made easily by adjusting the fence angle.

Downsides of a Crosscut Sled

While crosscut sleds have numerous benefits, there are a few downsides to consider as well:

Takes up space

The sled is large and needs to be stored near the table saw. This can take up precious real estate in a small workshop.

Not ideal for small workpieces

Cutting thin strips or other tiny workpieces can be tricky with the sled since it requires placing them along the fence. The miter gauge may work better.

More cleanup required

Wood chips and dust can accumulate inside the sled with use. Occasional cleaning is required to keep it sliding smoothly in the miter slots.

Initial setup takes time

Making an accurate crosscut sled from scratch requires careful setup, planning and calibration using precisely measured test cuts. This process can take hours.

Costly to purchase

Buying a manufactured sled with extensions can cost over $150. Making your own requires purchasing materials too.

Mainly designed for crosscutting

A crosscut sled excelles at crosscuts but not rip cuts. Operating a table saw without one takes more skill.

Do You Really Need a Crosscut Sled?

Whether you truly need an crosscut sled depends on a few factors:

What you build

If you regularly work on projects requiring extremely straight, splinter-free cuts across the grain, a sled is indispensable. The precision and convenience make certain tasks much simpler.

Experience level

Beginners will benefit greatly from a sled’s safety and accuracy. For seasoned veterans with top notch table saw skills, a sled provides helpful but non-essential enhancements.

Workshop space

Those with spacious shops have the luxury to house a large crosscut sled. For small garage shops, the footprint may be prohibitive.

Evaluating your needs and workstyle will determine if investing in a crosscut sled is worthwhile. They provide such usefulness for most woodworkers that lack of space may be the only barrier.

What Makes a Good Crosscut Sled?

If you determine that a crosscut sled is a wise addition to your workshop, be sure to build or buy one with these characteristics:

• Precisely square fence to blade (90 or adjustable degrees)
• Slots for miter bar to fit saw rails
• Sturdy plywood base
• Smooth runners underneath
• Hold downs such as cleats to secure workpiece
• Stops for repetitive cutting

A quality sled needs to slide smoothly in the miter slots but still stay firmly in position during cutting. Robust construction is essential – no wobble during use. Lastly, look for a large surface area to support sizeable workpieces.

Making Your Own Crosscut Sled

For woodworkers keen to build their own sled for a fraction of retail prices, here’s an overview of the process:

Tools and materials needed

• Quarter-inch plywood or MDF – approximately 24 x 30 inches
• Hardwood strips for runners – 1/4 x 3/4 inch
• Bar clamps
• Wood glue
• Screws
• Square
• Tape measure
• Router with straight bit (optional)

Cut plywood base

Cut the plywood to size allowing several inches extra length to accommodate long workpieces. Cut a center channel at maximum blade height.

Attach hardwood runners

Glue and screw hardwood strips underneath to ride in the miter slots. They should fit snugly but slide smoothly.

Attach fence

Clamp a straight piece of plywood or hardwood at exact 90 degrees vertically to the base. Glue and screw into place.

Calibrate sled

Perform test cuts on scrap wood, adjusting the fence until 90 degree cuts are perfect. Secure the fence permanently once calibrated.

Additional options

Attach hold downs, stops, extended side supports or other accessories to enhance the sled’s functionality.

Ready to Purchase? Quality Brands to Consider

For woodworkers who would rather skip the build process, several brands offer excellent pre-made crosscut sleds. Here are some top options to consider:

JessEm

JessEm makes the popular Rout-R-Lift II, a heav duty sled ideal for heavy use. Precisely machined runners ensure smooth travel. The large 30″ x 27“ size can handle big workpieces. JessEm sleds are flat, stable and built to last.

Woodpeckers

Woodpeckers has earned a reputation for precision woodworking tools. Their crosscut sleds feature robust construction and thoughtful details like hold downs and flip stops for master craftsmen.

Incra

Known for high quality fences and precision jigs, Incra’s sleds provide excellent accuracy. MagneGlide strips align the sled in miter slots flawlessly. The V27 and 5000 models are great choices.

Kreg

Kreg makes very affordable and functional sled kits for the hobbyist woodworker. Their precision trac fence cuts accurately. A compact size around 22“ x 24“ saves on space.

Rockler

Rockler’s sled kits come with precut cabinet grade plywood ready for assembly. Convenient features include hold down clamps, hand grips and router edge banding. Great for DIY builders.

Conclusion

Investing in a crosscut sled is highly recommended for any woodworker who values precision, safety and efficient cuts. The ideal sled has a flat true base, square fence, sturdy construction and smooth miter bar rails. For those short on space, compact sled kits under 24 inches wide are available.

Building your own sled is the most affordable option, with care taken on initial calibration being critical. For frustration-free convenience, pre-made sleds from JessEm, Woodpeckers, Incra, Kreg and Rockler offer quality and reliability. Whichever route you choose, adding a crosscut sled to your table saw will elevate your cutting accuracy and enjoyment of woodworking.

Frequently Asked Questions

What size crosscut sled is best?

For most home shops, a sled in the 22” – 28” range works well. Large professional sleds can be 30” or more. Just ensure it fits your table saw rails and provides ample workpiece support.

Is a crosscut sled necessary?

It’s not an absolute necessity but provides great benefits. A sled makes crosscuts safer, simpler and more precise. Most woodworkers find them indispensable.

What thickness of plywood for crosscut sled?

3/4” plywood is ideal to minimize flexing. 1/2” plywood is adequate if using several layers glued together or sturdy hardwood reinforcements. Avoid thin 1/4” plywood.

How thick should the runners be?

For miter slots 3/4″ wide, runners should be 1/4″ thick, with a 3/4″ height for a snug friction fit. Wider slots may need thicker runners.

Can you use a crosscut sled on a miter saw?

No, crosscut sleds are only designed for the miter slots on a table saw. On a miter saw, they would interfere with the saw’s function and safety guards.

What about outfeed support?

Long workpieces need additional outfeed support when cutting on a sled, such as rollers, tables or extra stands beyond the sled area.

How do you calibrate a crosscut sled?

Make test cuts in scrap wood while adjusting the fence until precisely square at 90 degrees. Check for blade parallel to miter slots also. Dial in any small tweaks.

Comparative Analysis

Here is a helpful comparison table analyzing the key factors when deciding between building your own crosscut sled or purchasing a pre-made version:

Factor	Building Your Own	Buying Pre-Made
Cost	Cheap (under $50 in materials)	Expensive ($100 – $300)
Skill required	Advanced skills needed	Little skill required
Time investment	10 -20 hours for planning, building, troubleshooting	Negligible, just unbox and go
Quality	Varies depending on workmanship	Predictably excellent
Accuracy	Hit and miss calibration	Calibrated accurately out of the box
Safety	Questionable reliability	Extremely reliable and safe
Size	Fully customizable size	Limited to standard sizes
Features	Basic with optional accessories	Decked out with everything
Resale value	Minimal	Holds value well if high-end brand

Expert Tips

For best practices when shopping for and using your crosscut sled:

• Ensure your table saw miter gauge slots are parallel front to back. Misaligned slots will wreck sled accuracy.
• Apply wax or silicone spray to the sled runners periodically for smooth gliding action.
• Store sleds upright on end when not in use to minimize warping or damage.
• Use hold downs, clamps or jigs to properly secure the workpiece when cutting.
• Check for blade or fence drifting which degrades precision over time.
• Use micro-adjusting screws to tweak sled calibration if cuts creep off square.
• Look for T-slot miter bars on premium sleds for maximum stability.
• Clean sawdust buildup regularly with compressed air and vacuum.

Following these tips will help you maximize the benefits of your crosscut sled and keep it performing accurately for years to come.