39 - Extreme Crosscut Table Saw Sled with Perfect Miter & Dado & Removable Zero Clearance Insert

I needed a crosscut sled to replace the ones that I keep ruining because I turn them into dado sleds every time a have to cut a quick dado. Doing this makes the saw blade opening in the bottom of the sled too wide to be zero clearance for the sawblade. And just as bad is when I have to switch sawblades out for one with a thin kerf.
I needed a way to make my cross cut sled have change-able zero clearance inserts for each different thing that I use. I figured if my table saw can have an insert plate, so can my cross-cut sled!
In addition, I wanted to have a miter sled. I don’t like pulling out my Incra Miter 5000 each time I want to make a 45 degree cut, like for a picture frame. So I designed a system that allows for absolutely perfect miters. I used the rules of geometry to cut and make a PERFECT 45-45-90 triangle. Anyone can do it, and I show you how. After I made that, I cut a perfect picture frame in less than 2 minutes.
And I not only cut dados with my dado blade, this Table saw sled combined with my dado blade makes a perfect tenoning jig, with flawless shoulders. I will show you exactly how to accomplish that with this sled. I hope you enjoy.

Things we used for this project:

(Rockler model no longer available)


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[KingsFineWoodworking]

PLEASE PLEASE PLEASE - SUBSCRIBE! It really helps us out.
Thank You ~James

[Katsoup]

James, I just want to say that as a fellow girl-dad, I really admire how your kids hang out in the shop and help you with projects. Mine are a little bit too young for that right now, but they like doing the "hanging out" part. Also, this sled is awesome. I might make an attempt at it at some point when I feel confident.

[geekazoid]

I really enjoyed the precision adjustment of the fence with 5-cut method.

[chuckhanson]

Great sled, well explained and easy to follow. Built the sled and it is true and wonderful to use. I made two changes. I used adjustable miter tracks that were top mounted to allow precision adjustments if necessary and I left a 1/4” gap at the end of the T-tracks so the clamps can be completely removed for some types of projects. Thanks again, really love your channel!,

[markpearson]

Ah young grasshopper - you have mastered the ancient kung foo glue down technique. :-)

[fusiondon]

I've been planning a new sled and just when I heard, "dado'ed the sled", I said A-ha!

That was the best idea I've been missing,
Thanks!

[GeeksWoodShop]

Your 45-deg method is killer James, you sir, continue to rock it!

[jerrys]

So you never told how you got the t-bolts in seeing that you ran the t-track full width. Why didnt you cut the track short on the far end???

[Jcarr]

By Far the BEST well thought out sled I have ever seen right down to the 45* block GREAT Job And Thanks You for sharing it with us!

[Larry-vkyk]

I have completed the build of this sled as per your excellent plans. Ques. Don't I need a perfect wood square to start the 5 cut method to begin with?? Thanks Larry

[paulkelly]

I'm old enough to remember watching "Lost in Space" and hearing the robot say "Danger Will Robinson"!

[kamac]

Beautiful sled, I particularly liked the reference to demolition man on your safety block!!! Nice touch

[DiHandley]

Definitely one of the better Woodworking channels on YouTube

[pierceit]

This is the best sled i've seen yet - love the dado option! I wish I could just buy one from you and then true it to my saw so I can spend my time making projects instead of jigs all the time... But now I gotta make this thing - love it!

[mcka-sifb]

"Advanced kung fu glue technique" lol...i laughed way too hard at that!

[GarryPrater]

Great tip on making the miter guide!
Also a great explanation of the 5-cut method. There is one slight error on adjusting the fence. Instead of dividing by the length of the fence, you should measure the length to the pivot screw since that is the point that stays in place. In your case, the dimensions are close so your method is pretty accurate but it might have been even more perfect. It would make more difference if the screw was not near the end of the fence.
Subscribed. Thanks.

[LeggedAdventures]

Hi James. i don't often question your methods but i did have a question when you attached the miter bars. being as wood doesn't hold machine threads real well, why did you not choose to counter sink on top and screw into the miter bar? As always its great watching you and the kiddos build amazing things. stay safe.'

[labrat]

Without any doubt the absolute best crosscut sled and cross cut sled build on youtube. Congrats. I will be purchasing the plans and building one.
 Only one possible safety improvement on your "death block", fit a stop on your outfield table. Mine is a 1/2 inch diameter bolt with the thread cut off and a large round rubber bumper fitted. It is positioned so that the saw blade is into your death block to the max depth for any piece you are going to need to cut without it coming through the back of the block. Your dado will also need its own hole due to differing diameter.  It can be stored on a rare earth magnet under the edge of the table saw top so it is always at hand. I've seen too many of those Safety blocks with saw kerf slots cut all the way through. All the best.

[thomasarussellsr]

Love the 5-cut and Geometric 45-45-90 systems, I'll have to remember those for sure. Thanks for sharing.

[pawpawstew]

Five years later, and this is still one of the best table saw sled designs out there.