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5 Cuts To A “Perfect” Cross-Cut Sled

The cross cut sled is probably the most important jig in your shop. I will explain the theory and calculations to enable anyone to get a sled dead on square. We’ll also show a few tips and techniques for constructing the sled.

You can purchase the full size mdf templates of the front and back fences at our store: Cross Cut Sled Fence Templates

Material List

Runners: 5/16″ x 3/4″ x 30″
Base: 1/2″ x 34″ x 30″
Front Fence: 1-1/2″ x 5″ x 30″
Rear Fence: 1-1/2″ x 5″ x 26″

Specific Tools Used

Mitutoyo Dial Calipers
4″ Brayer

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14 thoughts on “5 Cuts To A “Perfect” Cross-Cut Sled

  1. I’m working my way through building the cross-cut sled but have a question. I cut the runners and got the same sound when I lightly finger tapped them into the slots as on the video. Individually they seemed to move fine in the slots. When I attached them to the base the movement resistance is much more than the collective resistance to before they were attached to the base.

    I wonder if the miter slots are not “perfectly” parallel. Have you seen that before? My saw is a vintage Unisaw.

    I’ve tried marking sides of the runners with a pencil hoping I could determine where the rubbing was occurring but the maple is so burnished the pencil hardly leaves any graphite. I’m hesitant to just start randomly sanding the runners because I’m worried I’ll create excessive “slop” in the sled. Do you have any suggestions?

  2. Hi William,
    Made the sled and with the 5 cut process got within .002. I did make a mistake the first time which really confused and frustrated me. With the rectangular piece to the left of the blade I mad the first cut but I rotated the piece counter clockwise and continued doing that for the rest of the cuts. Error magnified! Looked at the video again and notice that the rotation is clockwise i.e the first cut line against the fence…end of problem. Might want to emphasis that a little more for us dummies.
    Thanks again,

  3. Hi William!
    Thank You for the detailed video and for simple and original metod “5 Cuts”! 🙂
    I was build my table saw from hand circular saw and from OSB pieces, from the remnants of laminate flooring and debris of old office desks. When I started working, it was not imagination that slots should be and how far from the blade. All done intuitively. Because I had no more precise tool, all the details I cut the same circular saw, using a guide line.
    When I put a circular saw into table, I started to build sled. Your video helped me a lot.
    And yesterday I finally made a “five cuts.”
    How do you think it passed my sled your test? My final piece has dimensions of 12.63 mm and 12.67mm. I’m pleased 🙂
    However, first I made a mistake and made correction in the opposite direction, increasing error.
    Now, thanks to you and Instrutstables (from which I came to your site) I can cut to within 0.04 mm
    Once again, thank you!

    1. Thank you for your comment. It never gets old hearing the 5 cut video helped someone. Congrats.


  4. So that I understand, is the fence you would be pushing on during use, the front or rear fence? Since one would be pushing the sled, I would think that would be the “rear” fence. When I look at the size descriptions above, it shows the front fence is longer (30″) than the rear fence (26″). But when I look at the pictures it looks like the longer fence would be on the end you’re pushing on which to me is the rear fence.
    Thank you!

    1. Hi Myron,

      The longer fence that you’re pushing I called the front because I’m standing in front of it and the shorter fence is towards the back. Hope this clarify things. Thanks for the comment.

      1. Thank you William for the clarification. I had it wrong.


  5. Sir, the suggested dimensions for the sled are as follows:
    Runners: 5/16″ x 3/4″ x 30″
    Base: 1/2″ x 34″ x 30″
    Front Fence: 1-1/2″ x 5″ x 30″
    Rear Fence: 1-1/2″ x 5″ x 26″
    My question is what would be a suggested Base dimensions if I wanted to make a smaller sled. I can ratio the fence dimensions. Is there a practical lower size limit for the base. For example I am thinking of a 20×24 or a 24×24. Do these dimensions make sense to you? Pros and Cons of making it smaller.
    Enjoyed your video. Thanks

    1. Fit it to your saw. Having it wider means you will have better support for longer work pieces and the ability to clamp stop blocks along the fence. Larger from front to back means you can cut wider panels. You will also want to adjust the front to back dimension so it does not fall off the back of the saw if you don’t have an outfeed table.

      1. Thanks…As I started to work on a sled I am not clear on a couple of points.
        Standing in front of the saw (normal cutting position with the fence to my right) and I place the sled base centered on the blade kerf is the offset of 1-1/2 to 2″ accomplished by moving the base towards the fence (right)or away from the fence (left)? Does it make a difference?
        After the offset the rear and front fence are centered on the blade…is this correct?
        Appreciate your help.

        1. Hi Jesus,

          It does make a difference. You want to off set it away from the fence so that the shorter side will be be near the fence. The fence is offset and is center to the sled. Hope this helps.


          1. HI William,
            Yes that clears things up for me. Thanks for your quick response…appreciate it.

  6. Dear Sir

    Are there PDF plans available to understand the size and amount of material needed for the cross-cut sled?

    Many Thanks

    Michael Pease

    1. We don’t currently offer paper or downloadable plans for the sled. It would differ table saw to table saw. We offer mdf fence templates which would help determine the width. You can see these here.

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