Making a Table Saw Extension and Cross Cut Sled | I Like To Make Stuff
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- เผยแพร่เมื่อ 27 มี.ค. 2019
- We made a cross cut sled for your table saw with an extra storage cabinet that extends your table saw surface! Check out the plans!
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Many people have asked me about the cross cut sled that I use in the videos. I made it long time ago and never showed it was done. If you aren't familiar, a cross cut sled is a squared jig that wood can ride on that will result in a perfectly 90 degree cut on the table saw. I used a lot of laminated plywood pieces pocket-holed together to make a front and back fence. These fences were attached to a plywood bottom panel. To ensure that it consistently runs straight along the saw blade, you attach thin strips of wood to the underside that ride in the table saw's miter slots.
That is basically it, a sled made of flat wood that runs in the miter slots, except that it isn't perfectly straight yet. To square up the back fence for consistent cuts, you use the "5-cut method." My cross cut sled was as close as I cared to get it, but be as exact as you like. Once the sled was square, I added some paste wax to the underside so it slid smoothly across the saw.
The idea behind this cabinet is that it would be a place to store the cross cut sled as well as other table saw items; extra blade, throat plates, my dado stack, and even my adjustable miter gage. There is room under the existing table saw extension to the right of the saw, but I thought I could use this cabinet to extend the saw's surface to the left as well.
I build a simple box on top of a wider platform with some drawer slides mounted on one side. The extra width at the bottom would allow for some adjustable feet underneath the cabinet without poking through the interior space. I also added some threaded inserts to the spot where the cabinet touched the table saw. The cast iron wing on my saw had some extra holes on that side so I could run a bolt through the saw and into the new extension cabinet. Using the adjustable feet, I made the top of the cabinet flush with the top of the saw and bolted them together.
Besides having room for the cross cut sled, I added a few drawer slide to the interior space to accept a sliding storage panel. This shelf would hold all of the other things I use on the table saw. Now, you could totally make some custom holders for blades or other items, but I'm super simple and just used some screws. I made a simple handle out of a scrap 2x4 and the interior storage space was finished!
Having the cabinet's extra surface space is nice, but it isn't quite big enough. I struggle with wrangling a full sheet of plywood on my table saw when ripping pieces. By adding a flip-up extension wing, I can now rip pieces off of a full sheet without it awkwardly tipping off the side fo the saw. The brackets I used to lift up the wing are rated for 300 lbs each, so I'm totally not worried about it collapsing under the weight of a semi-supported sheet of plywood.
I really love this new shop fixture. It solved a few problems I had with organization and saw capacity. Building a new, more accurate cross cut sled was an added bonus that rounded out the project. This cabinet can work for any saw you may have. If you use a contractor saw that folds up, the cabinet can be bolted to the side of it as well. If there aren't any hole in the end of the saw wing, you could just clamp it together from underneath. If you are interested in making one of these extension wing cabinets for your saw, check out the link to the plans down below!
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Making a Table Saw Extension and Cross Cut Sled | I Like To Make Stuff
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One of the (many) reasons I love your channel is the exceedingly healthy balance of actual project videos vs. shop improvement videos. Lots of makers these days only do stuff for their shops... Loved the video!
Love the fact that you show the mistakes as well as success! Nothing worse than a "perfect all the time" show !! Thanks for the inspiration
Finally someone who mentions their mistakes as they go along. We all make them and they are very important to mention as it saves others from making the same ones. Thanks for adding them in your video
I really appreciate watching you get yourself in and then out of difficulties.
" Oops, I made a mistake. Here's how I fixed it. " Fantastic
Here's how I fixed it
🔥🌋🔥
😅
I may forget everything else but that important lesson! :-)
That's some of the best parts, few others leave those in
A small thing to add to the sled is a chamfer cut into the bottom of the back piece on the side that faces into the sled. This will allow sawdust and other debris to be pushed into the space by the material you're cutting instead of having that junk pressed up between the back piece and your material, ruining your straight cut.
Great video and always looking forward to more!
I was going to suggest the same thing
Yea, out of the other 378 crosscut sled builds I've seen on youtube, 347 recommend a chamfer at the bottom of the push fence.
The first benefit of not gluing it down comes to light. Nice sled otherwise. My next project is one of these and a shooting board.
Why not use a little puff of air or a brush to remove the debris from the locating surface? That's why you work with wood instead of metal... lazier.
Judiciously choose the front-to-back distance of the sled to accommodate popular wood sizes - maybe 24" plus a tad?
Never new this was necessary but now that I understand it better I will be able to make better cuts when I get a table saw. Thanks
Oh how cool is that! Finally a place to stow the sled and accessories! Well done.
Thanks for showing the pocket hole boo boo. Let's me know I am not alone in this world. SKILL is directly proportional to ability to correct mistakes.
Milt Clark I thought the same thing. And when he had the blow out when he drilled the holes. It’s a great teachable opportunity to share how you work around. Cheers to you!
A much wiser (and somewhat older) man than me once said, "Experience is directly related to the number of failures, miscalculations, and piles of equipment destroyed."
No. You are not alone. ;o)
I recall a saying that you don't tell a carpenter by what he builds, but by how he fixes his mistakes!
Lol. First time I read this, I thought you were calling him "boo boo".
Everyone makes mistakes to hide them is where the skill comes in. Chances are no one will ever know but you, if you dont tell anyone about them.
Once you do you show everyone knows your human.
If you ever needed to adjust your DIY leveling feet/bolts more than once, I'd dremel in a small slit at the tip so you can use a flathead screwdriver to make small adjustments from above.
Also, I feel like I've heard the entire ILTMS music library in this video, and am reminded of how on point it is. One of my favorite parts of these videos...
Or you could just screw the bolts from the top
@@afonsoferreira5171 👍 my thought exactly !
Afonso Ferreira And use longer bolts to fit a locking nut to prevent them from working themselves out of alignment 😊
Or hire a team of ants to hold it in place
The salt trick works great. I've been using it for over 50 years now...I was told by a chemist friend that the salt will disolve in about 20 minutes. I have the same pocket hole jig. I don't know why one would want to continually upgrade this jig every time they come out with a new one. i have one that i bought over 30 years ago and it was the very first version that they made. All of aircraft aluminum except for the drill inserts which are steel. Still works great!!! Nice to see that someone made the same mistake that I did with the hole setting!!! I use those threaded inserts a lot - love them!!! Hex bolts - much better idea. Nice, well thought out video.
3.29mil subs and still uses a silver tape measure. True legend, and a great channel!
I'm so glad to hear you say "I actually goofed and..." Real world projects are filled with small goofs and it's good to see pros make small goofs too. Keep up the good work!
Agreed, one thing about Bob's videos is that he shows the mistakes that are common and how to fix them or avoid them in the future
Bob you are a certified clamp champ 🗜 🏆
I love the fact you don't edit out your mistakes, the best way to learn is by mistake and seeing someone else's mistakes makes the learning videos that much better. Thanks for being human like most of us!
Finally, very informative instructions for a crosscut sled, not only how to build one, but why one is needed.
Thank you.
Now that is how to make a professional grade instructional video. Great job! I had learned several things about a cross-slide that I wasn’t previously aware of. TY
Wow, your glue lines are incredible straight and even. Mine always look like I did it on a boat. Great job!
I really appreciate that you acknowledge that sometimes plans change or things don't work out as you are making projects. Being able to adapt your plans on the fly makes for a more realistic learning experience.
Nice and simple instructions. Thank you!
William NG has a great video to insure your that your back stop is perpendicular to your blade and explains how to use the five cut method to dial in a perfect 90 degrees to blade relative to the back stop. He also has a great video on how to properly chuck a Drill Bit.
William also uses digital Calipers for an even more precise 5 cut method.
Nice idea on the storage for the sled.
I love the 5 cut method. But since I'm OCD it also drove me insane to get rid of the .000004 out of square I just have to deal with....
That extension wing is seriously, super strong, stable, and sturdy. FIRST!
Hi, i dont speak english language, so i could understand a little what you are speaking , but learn a lot !! many thanks, i am from Colombia living in Panama. i am a self study carpenter!
I am a 76-year-old cabinet maker and I have "retired" but whoever really retires. I am getting the plans and will build one for my table saw when I get one for my hobby shop. I can tell without using this it will be GREAT!!
I was expecting a clamp champ sticker, not disappointed!
The method by which you squared the back fence was really helpful and new way for me, Thanks Bob, great content. Greetings from South Africa
Make sure your squar is true. Look on youtube how to do that. I've bought new framing squares that were not even close.
Thanx I enjoyed. Like the storage for the sled & all.
You have a big talent to explain things!
More of these garage wooden organization videos! Love loved love it! And of course your renovations are fantastic! I love the wooden builds
An outstanding video Bob! What a great addition to any table saw. So useful and cleaver. My saw is on wheels ( garage shop) to be moved around as needed (wife's car) but I am going to look into this further to make the concept work in my situation. Thanks for the video, another helpful addition to my work working!
Great point Jb. I wonder how I could make it and use castors instead of feet.
HMMMMMM! Jim
Same here. I am going to try adjustable hight casters on my box build.
Nice that you offer plans. there is invariably somebody in the comments section asking about them. Although that usually makes me shake my head. I'm just a hack Carpenter with some tools. But after watching your extremely well documented video, I don't know why someone wouldn't be able to make a simple box.
I learn so much, so much ideas, so much materials, you are amazing
Does anyone else get super happy when they see "clamp champ"
YES
Every time 😂
Never heard of using salt to keep boards from sliding while gluing them up. Awesome!
Keep on going - wish you the best from over here in Germany!
And I wish the from over here in Austria (NOT Australia)
I tried this once. Ran inside and grabbed the salt grinder from the kitchen....Bad idea. Make sure the salt is fine.
I've never really liked the idea of adding salt to a glue joint... just feels wrong somehow lol. If you don't use half a bottle of glue, it won't slide around too bad.
@@BEdmonson85 Me too. Salt attacks everything given time.
@@BEdmonson85 Use inert grit, like very fine sand, near-powdered hardwood sawdust, and any very fine, hard particle. A matching kerf running near full length of the joint filled with ice cream sticks forced into both pieces aligns and strengthens.
Dowels are a bit of trouble, but prevent joint slip. #10 copper wire either spaced along the joint as short pegs, or mashed into a shallow grove in both parts will not dull saw blades but will prevent slip.
I have my pieces for a cross cut sled cut, but I had not put them together yet. I had some questions. You answered my questions in this video. I appreciate the way you explain things. You offer the reasoning behind the plan. Love that you have kept this simple and focused on the key elements for the sled. The design for the extension is awesome. By the way, I made your miter saw station and it makes me happy. Thanks, Bob!
Thanks so much! That's awesome to hear!
I like this upgrade. I have a small garage workshop and a small table saw that I wish could handle a sheet of plywood. This looks like something I could work with in the small space I have in the garage.
Hey Bob ! You should consider making a pool (billiard) table. It will be a huge success !!!!
Skillful that he is, I'm sure he can. And will absolutely smash it.
Great project. I really love the storage idea for the sled, I need that.
I’ve watched a lot of crosscut sled videos and this is, by far, the simplest one I’ve seen. I also modeled my miter saw station off of yours because it was so simple but really effective. I’m sure shop furniture isn’t your favorite thing to work on, but you have an amazing knack for making it accessible to beginners like myself.
Really cool method showing us the 5 cut method! Awesome video
Good stuff! You could also insert the adjustable feet bolts from the top for easier adjustment. Not much difference between the bolt head and the bolt “foot” touching the ground but then you can easily adjust it from above.
Thanks! (Was going to suggest same if someone else hadn't.) :-)
When you use your framing square to line up the fence try sticking a couple of nails in the slot about 12 inches apart then you can butt the square up against the nails rather than rely on sight or feel. Nice build.
I need more clamps......Great idea that I will definitely use to enhance an old saw I inherited. Thanks for leaving in the few errors you made which allows you to show us how to fix them.
I love that you always show when you screw up to let the rest of us know that even the best Makers do make errors.
Could you make a Bits video on types of plywood and their uses?
..and a video on glues, how they bond and how much to use would be useful.
@TOFU豆腐 Thanks - I'll go have a look. Cheers!
@TOFU豆腐 Good summary - thanks TOFU
.
2:10 Tip!: I also added some pepper, oregano, red peppers, some unions, cheese and, salami. Although it was a first for me, didn't taste all that bad!
Love your videos. This is exactly the kind of project that I love and have been needing.
I really admire that you keep the goof-ups in the video. It’s valuable to see how you work around it.
As a novice, your channel has had a lot of value for me.
Thanks!
Really like your down to earth video which included correcting the occasional “OOPS” which all us fellow woodworkers encounter. Some great ideas on the table saw storage. Many thanks!
When that guy told you, "You can never have too many clamps", you took him seriously.
You missed an opportunity to try out pocket hole plugs. Plug the error-holes. If it does not turn out well, no big deal; they're out of sight.
When doing the 5-cut test, you always turn the piece such that the side you just cut is against the fence.
Put a stop block on that back of the sled that hits the table before the face of the fence gets past the center point of the blade.
Those things you call guards are called inserts. A guard covers the blade from above.
Learning about woodworking and research table saws. Once again a homeowner so can't wait to do DIY stuff in me house.
I loved your humility in admitting your mistake/s. I love this whole idea and plan to make it for my table saw. Thanks for sharing your knowledge.
Can you even imagine how frustrating it would be to have to preface every other fastener with a disclaimer? "Now nails aren't for every situation, but for this, they're just fine."
You can't be a woodworking TH-camr without apologizing for using pocket holes every time you use them. It's in the manual.
Hey Bob hope you’re doing well. I have a question though! I was under the impression that those 90° table wing extensions, are proud of 90° due to the weight they will experience when fully extended? Either way truing them to a perfect 90 was probably a great idea but I’m curious to know will it hold that 90 for months to come!
The cubbyhole for saw accessories is genius by the way love that idea
Same thought here , those extra degrees are there for a reason since they are supposed to hold about 300 pounds.
I think it might be designed with the assumption that the material it's holding up will sit flush when extended and would be responsible for stopping it at 90 degrees. The bracket then is designed slightly proud to put a little extra force on the joint to counteract any weight on the table. He should have tried mounting the table up before seeing if he needed to add shims. Works either way, but I would expect the proud angle on the bracket isn't a manufacturing flaw.
Ryan Legner yes. I believe you’re right. Good point
Found the plans on Etsy thanks this is just what i needed for my small table saw .
Great video and I love how you address issues that come along whether that be issues that you made or issues with the products you use (you buy) that you have no control over. Some people mess up and then redo the clip so it makes them look better. We’re not perfect. We mess up. And owning it and correcting it is a good way for all of us to learn.
Thanks for the videos. Love them.
Shop: how many clamps u want?
ILTMS: Yes
Another answer. More. Why are clamps always 1” too short? Nice build!
"" you can pour on salt. you dont need much''
puts on a kilo salt XD
We’res the pepper I’m hungry 😋
Robin, I am getting a new saw next week and you have given me the inspiration I need for side extensions.
Amazing video!! I liked how you explained everything in detail.
Went to the clamp store and said, 'give me all you have'
What about using melamine as the base board. It would be more slippery
Melamine works great. Better if its only coated on the bottom so you can get a little traction on your work piece. Don't need it slipping around on the top while you're making cuts. You could probably rough up the top a little with some 40 grit or glue down a piece of sandpaper if you wanna go all out.
Using sanding sealer on MDF works good as well. Leaves a smooth waxy finish.
Really love that you got the brackets, saw they weren't perfect, and instead of writing them off as junk, you stayed positive (on camera at least) and just figured out how to make them work.
Hello I'm French and I look very much your's video, you explain very good the process to create any thinks. Yank you very much
From your Example of the 5 Cut method, it looks like you did it wrong. You turned the un-cut side forward instead of against your fence. In addition, a couple things to really improve the accuracy, 1. use the largest piece of wood you can on the sled to get the longest distance. 2. use a caliper instead of ruler, the accuracy is much better.
Another item to use, when squaring the fence, place a straight edge in the cut kerf of the sled and use the square against that to your fence.
I know you were just hacking together a quick sled, most of these ideas are for your many followers when building their own. Thanks Bob!
In fairness, he did say to check online for the specifics on the 5 step method and wasn't really demonstrating how do do it. :)
you should have done the 5 cut before securing the fence
He did!
This "The Best" demo video I have seen, OUTSTANDING! Thank you!
Really love that you leave in the "oops" moments and how to fix it or work around :)
Shouldn't you test your fence for square before you screw it on all the way across, by cutting some wood?
Step 1: Buy $1000 worth of clamps
😂
That's the dream
The fact you show your errors and that whole shimming the brackets thing is why I love your channel.
True testament to the evergreen content of TH-cam! This just popped up, pretty randomly. Conveniently enough, I need to build an extension for my new Sawstop... I also really appreciate how you show and fix your mistakes in this video. I know all the mistakes don’t make the final cut, but seeing you (or anyone) make mistakes and show the solution is always helpful.
Wait I like to make stuff there can only be one move along bucko
Extremely well done video, but hated the music. Very distracting and gave me a head ache.
I LOVE this channel. Professional through and through. There isn't a single video that fails to teach clearly and understandably.
Wow, great idea!! That is a great way to basically force yourself to stay organized but yet have it accessable when needed. Always a big obstacle in every wood shop. Will definitely incorporate this into my shop.
Pocket holes are evil and must die :-D
That is an awesome little project, which adds a lot of functionality to your tablesaw! Simple things are the best! Who in the world are the 350 yoyo's that didn't like this? Man, oh man, some people...you'll never please, so why bother, and why worry?, because they'll make themselves old before their time with all those sour notes, while the rest of us will be groovin', and sailing along just fine without them!! Thanks, bro, for sharing this!
Good explanations for the project and great tips useful to the newbie - Excellent video !
I enjoy that you show your mistakes and how you proceeded after you noticed them. Keep up the amazing content.
This video provided the answer to three issues I have been needing to address in my very small shop. The need for more storage space particularly for my table saw jigs, and out-feed table and a method for leveling tables that I already have in my shop.
Excellent video I got a lot out of it and will be applying what I learned in my shop. Thanks for the tips!!!
This video was the simplest explanation I have run across for how to make a crosscut sled. The storage features and the table extension were just bonus' for me. Thanks so much for sharing.
Quite probably the best how to video on TH-cam
Own it you rock.
I love your videos they’re real they show your mistakes and show a real person doing real life work.
Appreciate you acknowledging a mistake with the pocket holes. Makes the video real world. I am a beginner and seem to make a lot of them 🤣
this video on building a table saw extension has impacted my interest on using a TS and the know how to build a portable extension... thx, and BIG UPS on your detail instruction
I like that you are so practical. No big deal with the pocket hole boo boo in this application. Your sled is square within 1/64" should be good enough for anyone!!!
That's reality and I am a perfectionist!
Thank you
Ingenious tip about adding salt to a glue up to help prevent the pieces from sliding out of alignment. Simple solution to the hinges not being square, using tongue depressors as shims, brilliant!
Most instructive cross cut sled video I've watched. Also like how you point out your mistakes or situations you get into and how you corrected/adapted. That's the toughest part for me.
Really enjoyed the project and storage of the sled. Great idea. Also I really appreciate that you leave the mistakes in and tell us about them!!! What a huge help that is. Thank you!
Loved the fact that you gooned up the pocket holes and had to do them again!! Shows that even the pros can make mistakes! :)
You totally CRUSHED that side cabinet to fit the cross cut sled along with the table saw accessories Attaching it to your table saw AND having a fold up table top was that much better!!
What a GREAT idea...consider your idea copied by me!!
I love everything about this....Thank You!
The beautiful thing about your style Mr I Like To Make Stuff, is you blend in a lot of info, but keep the project moving. That is a very nice skill.
That's what I call "lectured without being lectured"!
Smart design! I’m going to make one for my. Thanks for posting!
Excellent this is the best slide construction I have seen. this is my third this evening and this one made the most sense and actually made me believe I can make one that is perfectly square. thanks. I liked and signed up to learn more.
I think it's a great build! It's simple, easily constructed, and makes a great storage place for things that usually don't have a home or aren't as close as they need be when you need them.
Let's face it!, who wants to walk half way across the shop to grab some clamps off the peg board or search through a cluttered drawer to find your dado blades? With them being at the machine, where they're needed, you get much more done... (that way you have time for other things!!).
Didn't know about those brackets before watching. Now I will mount EVERYTHING WITH THEM!
They're great!!
I used them for an outfeed table attached to the back of my cabinet saw
So great to see something simple that is so useful. Have seen so many cumbersome sledges that do exactly the same. Great job
Thanks Bob! Been meaning to make a crosscut sled for a while, love the simplicity of your design and the thorough, yet understandable explanation!
Excellent, thanks!
I do love watching you at work. You make it look so easy, which is kinda inspiring. This is a great project. Thanks.