Crosscut Sled Zero Clearance Insert - Router Forums
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post #1 of 16 (permalink) Old 05-30-2015, 09:39 AM Thread Starter
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Default Crosscut Sled Zero Clearance Insert

Has anyone attempted or had success with retrofitting a tablesaw crosscut sled with a replaceable insert? I'm considering my options before committing to replacing the base. i can think of many issues that might come up keeping the insert flush, etc but it might be worth the effort. My base is 1/2 in baltic birch.
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post #2 of 16 (permalink) Old 05-30-2015, 10:16 AM
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Just build the sled and make the cut. Then when it wears out just fill it with Bondo and cut it again. This can be done many times and makes for an accurate slot.

Al

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post #3 of 16 (permalink) Old 05-30-2015, 10:29 AM
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Quote:
Originally Posted by FreeTime View Post
Has anyone attempted or had success with retrofitting a tablesaw crosscut sled with a replaceable insert? I'm considering my options before committing to replacing the base. i can think of many issues that might come up keeping the insert flush, etc but it might be worth the effort. My base is 1/2 in Baltic birch.
yes...

flip it upside down...
set a guide for your router to the sled.. leave it be till finished...
rout a dado ¾'' wide or wider (wider is more gooder) by ¼'' deep centered to the saw kerf/slot...
add fasteners tthrough the base and into your cross bars about an inch from the dado to kill any hope of flex or movement....
change to a ½'' bit and through cut a second slot...
you should now have matching and opposing rabbets... a rebated/shouldered through mortise???
make ''T'' shaped filler out of Redwood, Cedar, VGF, hard Maple or White Oak (in this order)... Remember, the more vertical the grain the better...
concentrate on a snug fitting piece that is super flush to the top side... proud to the bottom by a fuzz is okay/good...
this a sneak up on it fit..
glue the piece in.. do your glue squeeze out clean up immediately...
that slightly proud to the bottom comes in really handy when you rig up some cauls to keep it pressed in...
use a smoothing plane or a LA block plane to flush up the insert...

I near rough cut the insert and then use a shoulder plane to achieve perfect fit...
1st time around.. an hour or so... once done you'll be able to apply what you have done here to other kinds of projects down the road...
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post #4 of 16 (permalink) Old 05-30-2015, 11:31 AM
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On my shop made sleds I had a separate strip where the saw kerf is and when it wears out I remove and replace it. It starts out as one strip and goes to 2 when it is cut lengthwise.

Herb
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post #5 of 16 (permalink) Old 05-30-2015, 06:29 PM
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Here you go Mark...

I made one with a replaceable ZCI..

http://www.routerforums.com/twoskies...scut-sled.html

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post #6 of 16 (permalink) Old 05-30-2015, 06:41 PM
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Default Crosscut Sled

[quote=TwoSkies57;660305]Here you go Mark...

I made one with a replaceable ZCI..

The thread is still there, but the pics are gone. I am interested...any chance of posting the pics again?

Marc
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post #7 of 16 (permalink) Old 05-30-2015, 06:44 PM
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Try it again Marc... lots of pics, takes time to load...

"..... limited only by imagination"

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post #8 of 16 (permalink) Old 05-31-2015, 09:08 AM
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Just to give you guys an update on this sled after 6 years of use. Only 1 design issue and its a biggie. The thing is a TANK. and weighs a bit more than what might be considered comfortable for alot of folks to use. The 2nd is that after 6 years, the walnut fence now has a very, very minor bow. Not much, but enough to make a degree or two error when using it for 90's. On narrow pieces, not such a big deal, but on wider stock, it adds up.
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post #9 of 16 (permalink) Old 06-01-2015, 07:03 AM Thread Starter
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Thanks guys for all the great ideas and input. Now I have to pick an approach Too many options
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post #10 of 16 (permalink) Old 06-01-2015, 12:46 PM
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Quote:
Originally Posted by FreeTime View Post
Has anyone attempted or had success with retrofitting a tablesaw crosscut sled with a replaceable insert? I'm considering my options before committing to replacing the base. i can think of many issues that might come up keeping the insert flush, etc but it might be worth the effort. My base is 1/2 in baltic birch.
Maybe this helps you a little:

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