5-Cut Method Table Saw Sled Squaring: Rotation, Rotation, Rotation
I've spent a lot of time in the last day trying to square up the near fence on my newly constructed crosscut sled. I finally succeeded in getting it within 0.002" over 30", after the tenth attempt!
I thought I had this nailed after viewing William Ng's video and I went into the shop ready to whip it out. Everything seemed to be going very well initially, but then I could never get even close. I'd do the 5 cuts, being as careful as I could with every aspect. I kept chasing as it would get worse, then I'd start over. I was running out of room for new screw holes. I was about to give up and just eye-ball it with my large steel square. I even went back to the video a couple times to be sure I was doing each step correctly.
Last viewing, it dawned on me. I was rotating the plywood panel the wrong direction! William was rotating the panel clockwise so the most recent cut was against the fence. I was rotating it counter-clockwise. Instead of five cuts, each one accumulating the error, I was turning the panel to a side that had not just been cut each time, so the angles had no bearing to each other as far as accumulating the error.
As soon as I rotated the panel the correct way, I nailed it on the first try.
Pictured below is the nearly finished sled. The corners have been rounded, fence edges radiused and the bottom waxed. Prior to waxing, it slide ok, but took a slight bit of effort and there was one spot where it hung up a tiny bit. After waxing, if I'm not careful, with a very modest shove, it will sail all the way off the rear of the table. All that is needed now is the little guard box over the near fence blade exit.
I can now get on with using it and more importantly, get on with making a small workbench for my granddaughter to practice hammering, drilling and sawing. She is pretty pumped for that "I'm going to help you with everything".
BTW, DesertRatTom, I set her up to saw in half a dozen popsicle sticks for a project she and Mom were working on, making corral fences for the farm animals of her Brio wooden train set - using the Japanese pull saw you put me on to. Ganged the together so it was one single sawing operation, but she managed it like a trooper.
"Quality is like buying oats. If you want nice, clean, fresh oats, you must pay a fair price. However, if you can be satisfied with oats that have already been through the horse, that comes a bit cheaper."