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Make A Bandsaw Crosscut Sled

By Willie Sandry on May, 9 2022
Making A Bandsaw Crosscut Sled

Most serious woodworkers have a crosscut sled for their tablesaw, but do you have a crosscut sled for the bandsaw? They’re a handy accessory that will let you cut dowels and small parts to size with ease and precision. Have you ever tried to cut a short dowel to length at a miter saw? If so, you know how hazardous it can be, and usually results in the dowel ricocheting off several walls of the shop before coming to rest in an indeterminate location. Solve the problem once and for all with a durable DIY crosscut sled for the bandsaw.

 

trimming Baltic Birch plywood at the Laguna Fusion table saw

Start by trimming a piece of ½” Baltic Birch plywood to 13” square at the tablesaw. This will form a stable base for the bandsaw sled.

 

Applying contact cement with a paint roller

Apply contact cement with a smooth paint roller to the Baltic Birch plywood, as well as a piece of plastic laminate. Let the contact cement dry to a glazed appearance, before applying the laminate to the substrate. Finally, apply firm pressure with a J-roller or workpiece support roller from the shop.

 

Trimming the laminate flush with the plywood base using a compact router

Trim the laminate flush with the plywood base with a compact router and bearing-guided flush trimming bit.

 

Installing the dado blade and sacrificial fence on the F2 Fusion tablesaw

Install a dado blade and sacrificial fence on the tablesaw for the next step. Cut a shallow rabbet on one edge of the jig base to receive a ¾” plywood fence. The rabbet only needs to be about 1/16” deep.

 

adding a shallow groove on the bottom of the plywood base

You’ll also need a shallow groove on the bottom of the plywood base to receive a hardwood runner. The location of the groove is determined by the size of your bandsaw. I’m building this crosscut sled for a Laguna 1412 bandsaw, so the groove is located about 3-1/2” from the edge of the plywood. The width of the groove needs to match a hardwood runner that fits precisely in the miter slot of your bandsaw. So make the hardwood runner first, and mill the groove to fit the runner.  

 

Securing the runner permanently with glue and clamps

I previously sized a hardwood runner to the miter slot in my bandsaw table. Aim for a fit that lets you slide the runner back and forth without any binding. If you were careful setting the width of your dado, the runner should drop right into the groove with a friction fit. Secure the runner permanently with glue and clamps.

 

pre-drilling and countersinking holes screws

Next, pre-drill and countersink holes screws that will attach the fence to the plywood base from underneath. A drill press makes quick work of these repeated holes.

 

Gluing the fence in place

Glue the fence in place, making sure it stays square to the jig base.

 

Reinforcing the glue joint with wood screws

Reinforce the glue joint with five #8 x 1-1/2” wood screws, for a sturdy fence that will last for years.

 

Installing the track system on top of the fence

Install the track system on top of the fence with four 5/8” long pan head screws.

 

adding the self-adhesive tape measure to the track

Next, add the self-adhesive tape measure to the track. Set the stop block a known distance from the bandsaw blade (shown with 10” wood block) and align the 10” mark with the cursor on the stop block. Press one end of the tape in place, then remove the stop block to finish installing the adhesive tape.

 

testing the bandsaw crosscut sled on the Laguna 1412 bandsaw

Now give your new bandsaw crosscut sled a try. It’s the perfect accessory to cut dowels or loose tenon stock to length for your projects.

 

make quick and accurate work of trimming small parts with bandsaw crosscut sled

With your new crosscut sled, you’ll make quick and accurate work of trimming small parts to length in the shop. Get busy in the workshop this week, and start by making this handy crosscut sled!

 

Willie is a Freelance Writer for several woodworking magazines, blogger, and YouTube creator who enjoys making traditional arts and crafts style furniture.

Find tips and tricks on his channel The Thoughtful Woodworker.

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