I have seen several posts pop up about cross cut sleds and their size. I was going to wait until I have everything completed before I posted this but "everything" is a lot and it may take a while. So here goes.
I made this crosscut sled bigger than my saw top. It overhangs the edges by 2" per side and on the back by 4" or so. The "table" is made from phenolic ply and I used Dominos joint two pieces together to make it big enough. I routed groves in it for T-trac and some hold downs. The cross members are 2" maple. The fancy design was "just becasue" I wanted to. The Eyebolts on the 4 corners are so it can be "hooked up" and lifed via pully system to the ceiling and then lowered when I need it.
The runners are the incra miter track.
Here is the "inovation" I thought of that I have never seen published. Maybe it has but I had not seen it. the trouble is always aligning the "fence" to the blade. So I made a partial cut and not through the maple. I got as close to the maple as I could. I then used 1/8" ply and wedged it to one side of the blade groove and used the ply as the reference to my square. I got the fence squared, clampled the cross member down and screwed it from the bottom.
I have built a couple of other cross cut sleds. They were always too small or not exactly square etc. This one slides like a dream and cuts dead square.
I think I still want to add an interior fence with the Kreg track and stop system. But that is for another day.
Hope this helps someone.
Todd
2008 Contributor