Accurate crosscuts

I am having difficulty with crosscutting panels and getting them square and exact which is necesary for dovetail joining.  I have a chop saw (power miter saw) but that only cuts widths of up to about 8 inches.  I tried making a crosscut sled for the table saw with one runner but it is not very accurate and useless.  I have thought about a sliding type chop saw. I'm also considering an aftermarket crosscutting slide to attach to my tablesaw. What do you think is the best choice?  I am interesting in cutting panels for casework and doors..

Marquette, MI      

Our Expert

Crosscutting wide panels for doors and tabletops is a challenge. The miter gauge on many tablesaws does not provide enough support to the stock for an accurate cut. I have a sliding mitersaw which does a great job but it is limited to a twelve inch wide panel. Aftermarket accessories which attach to the saw are wonderful tools but they are somewhat expensive and unless you operate a production shop they may be out of your price range. 


I suggest that you make a second attempt at the crosscut sled. I've included a photo and drawing of the one I use in my shop. To fine tune the sled to cut precisely 90 degrees, I make fine adjustments to one end of the sled runner. Once the sled cuts square I fasten the runner securely with an additional screw. It can be a bit tedious but once set up a sled is a great way to cut a perfect 90 degree angle on wide panels. However, one drawback to the sled is that the runners wear. I solve that by using hard maple for the runners. Also, when using the sled I push it gently to the left (away from the blade) as I push it forward. This compensates for minor wear on the runners.


Also, I don't use use of the crosscut sled for stock thicker than 1-1/2". Otherwise you'll risk weakening the frame members at the front and back of the sled. 


To construct the sled in the drawing here are the steps that I use:

1. Cut a 3/4" plywood panel to fit the top of your saw. My sled measures 3/4" x 26" x 40".

2. Mill two strips of maple to fit in the miter slots on your tablesaw. The strips should fit precisely because they serve as the runners for the sled.

3. Fasten one runner to the plywood panel at 90 degrees.

4. Now fasten the frame members at the front and back of the sled. 

5. Attach the guards. The guard at the rear of the sled is just a block that is glued to the frame. The block keeps the blade buried at the end of the cut.

6. Test the accuracy of the sled. If necessary make minor adjustments to the runner. Once it is cutting square attach the second runner to add more stability.

For smooth, splinter-free crosscuts I use the Amana Tool Prestige saw blade. And because it is a combination blade I can keep it mounted on the tablesaw when ripping.


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