I made a table saw miter jig for my crosscut sled FREE PLANS

Table saw miter jig for the crosscut sled | FREE PLANS

Build a workshop | Free woodworking plans | Woodworking jigs
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The fact that you ended up on this blog can have two causes.

Either you see the benefit of this table saw miter jig and want to know how to make it for your workshop, or you wonder why the hell you should make this table saw miter jig. Eventually, a table saw blade can tip, I hear you think.

Well, if you ask me, this jig has a lot of reasons why you should make it. Besides making accurate cuts, other advantages are efficiency and speed.

Taking a crosscut sled off the table, readjusting the saw blade, making a cut, and then doing the entire process back to front takes noticeably longer than placing this jig onto your crosscut sled and adjusting it to the correct angle.

Even if it is for one cut, you will still be faster with this table saw miter jig.

So, when you’re here for the second reason, I’m pretty sure you’re already convinced this table saw miter jig is for you.

In this blog, I will explain step by step how to build it.

Let’s go!

Before we start building

To prepare you for building this table saw miter jig for your crosscut sled, I have made a few handy lists.

In addition to a few personal protective equipment that I use*, I also list the materials as well as the (power) tools you will need to build this jig.

* Safety is always your own responsibility!

Building this table saw miter jig step by step

This table saw miter jig is custom-made for my crosscut sled.

If you want to build this crosscut sled yourself, you can!
Earlier I wrote a blog about how I built this crosscut sled. There you can see step by step how you can build this crosscut sled yourself.
This blog also includes handy downloadable plans.

Step 1 | Making the jig

First, cut your plywood to the correct sizes.
These sizes can all be found on the free plans that you can download in this blog.
So don’t miss those plans!

To cut these pieces, I used my crosscut sled. That way I’m always sure my pieces are perfectly square.

I made a table saw miter jig for my crosscut sled FREE PLANS

I rounded the sides of this table saw miter jig.
This is to make the jig lighter, to have a better overview, and to give the appearance of the jig a modern look.

I made this rounding with a router and a straight cutting router bit.

To give the edge a perfect shape I used my router circle jig.

To place the jig I drilled a hole in this part at the point where the adjustable part of this jig will later hinge. The dimensions for this hole can be found on the free plans.
The diameter of the hole is adjusted to the dowel that I used to make the hinge point. In my case, this is 8 mm. Adjust that diameter if you would use a different size of dowels.

Tip:

Discover which router bits you really need for your workshop.

Visit my blog where I explain how you can finish 95% of your projects with just 5 router bits.

Recommended!

I made a table saw miter jig for my crosscut sled FREE PLANS

To make the slot in the side panels you can just reset the router circle jig and repeat the previous steps.

I made a table saw miter jig for my crosscut sled FREE PLANS

Once the side panels were made I could make the adjustable part of this table saw miter jig.

In this part, I drilled 4 holes in the sides of the plywood.

2 holes are used to connect this piece to the side panels. These are also the pivot points of this table saw miter jig. Dowels are put in these holes.

The 2 other holes are used to clamp the table saw miter jig in the correct position. Threaded rods are glued in these holes with epoxy glue.

I made a table saw miter jig for my crosscut sled FREE PLANS
I made a table saw miter jig for my crosscut sled FREE PLANS

Ok, now all the major parts for this table saw miter jig are ready.

With my corner clamp, which I made a few weeks ago, I could now make the first connection.

Under no circumstances should you glue that connection. If you still have to adjust the adjustable part for some reason, the side panels should be able to be removed again.

I have done this connection with screws.

I made a table saw miter jig for my crosscut sled FREE PLANS
I made a table saw miter jig for my crosscut sled FREE PLANS

After the first side panel was mounted, I was able to connect the adjustable part.

Then I clicked the side panel on the adjustable part from the other side and also secured it with screws.

I made a table saw miter jig for my crosscut sled FREE PLANS
I made a table saw miter jig for my crosscut sled FREE PLANS

Step 2 | Making the knobs

I made a table saw miter jig for my crosscut sled FREE PLANS

To fix the table saw miter jig in the desired position I used home-made knobs.

The jig I used to make these knobs can be found in another blog and video of mine, along with a step-by-step description video of how to make these great buttons yourself.
So be sure to take a look at that blog.

I made a table saw miter jig for my crosscut sled FREE PLANS

I could now screw these knobs onto the threaded rods that I had previously glued to the adjustable part.
To make the knobs firmly connected to the wood, I installed a washer in between.

I made a table saw miter jig for my crosscut sled FREE PLANS

Step 3 | Connection to the crosscut sled

The jig is now almost ready. However, if I had to put this jig on my crosscut sled and start cutting then this table saw miter jig would shift. Not only is this dangerous, but it also compromises the correctness of the cuts.

That’s why I made a simple part that can clamp the table saw miter jig firmly to the crosscut sled.

This part is nothing more than a strip of wood with 2 holes that is attached to the jig.

For that confirmation, I used wood glue and brad nails.

I made a table saw miter jig for my crosscut sled FREE PLANS
I made a table saw miter jig for my crosscut sled FREE PLANS

Bolts were placed in the t-track of the crosscut sled fence and the strip with the holes was placed over these bolts.
Again, I placed washers to secure the connection.
The buttons I used here have a smaller size. The star buttons were too big to use here.

Watch this blog and video to see how you can easily make these buttons yourself.

I made a table saw miter jig for my crosscut sled FREE PLANS

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How to use this table saw miter jig

Using this table saw miter jig on your crosscut sled is really easy.

All you have to do is set the correct angle you want to use.
For this, I used my digital angle finder.

To do this, first, measure the zero point by placing the digital angle finder on the side of the saw blade. Now recalibrate the digital angle finder.

Then you attach the digital angle finder to the adjustable part of this table saw miter jig. Now move the adjustable part of the jig until you get the angle you need for your project.

By clamping your workpiece to the jig you can now cut the edge at any angle you want.

I made a table saw miter jig for my crosscut sled FREE PLANS
I made a table saw miter jig for my crosscut sled FREE PLANS
I made a table saw miter jig for my crosscut sled FREE PLANS

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I’m looking forward to see you soon in another blog or video.

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