Small Crosscut Sled for Table Saw DWE7491RS

Introduction

This tutorial guides you through building a small crosscut sled for the Dewalt DWE7491RS table saw, inspired by designs for mini table saw sleds. A crosscut sled enhances accuracy and safety while cutting, making it a valuable addition to your woodworking toolkit.

Step 1: Build the Fence

• Materials Needed: Birch plywood for the body, oak strips for the runners.

Cut the Fence

• Measure and cut a piece of birch plywood to serve as the fence.
• Ensure the fence is square to the base for accurate cuts.

Add T-Track

• Create a slot for the T-track along the top of the fence.
• Use a router to cut the T-track slot, ensuring it fits the T-track hardware.

Step 2: Create the Base of the Sled

Cut the Base

• Measure and cut a rectangular piece of birch plywood to the desired dimensions for the sled base.
• Ensure the base is large enough to support your workpieces.

Attach the Fence

• Secure the fence to the base using wood glue and screws.
• Make sure the fence is perpendicular to the cutting edge of the sled.

Step 3: Install the T-Track Stop Block

Making the Stop Block

• Cut a piece of wood to use as a stop block.
• Drill holes for the T-track bolts to secure it to the fence.

Attach the Stop Block

• Slide the stop block into the T-track and adjust it to the desired position for repeated cuts.

Step 4: Fabricate the Runners

Cut the Runners

• Cut two strips of hardwood (oak) to fit the miter slots of the table saw.

Shape the Runners

• Ensure the runners fit snugly in the miter slots without being too tight.
• Sand down the edges as necessary to avoid any binding.

Step 5: Assemble the Sled

Attach Runners to Base

• Secure the oak runners to the bottom of the sled base using wood glue and screws.
• Ensure the sled glides smoothly in the miter slots.

Step 6: Add a Self-Adhesive Measuring Tape

Install Measuring Tape

• Cut a length of self-adhesive measuring tape.
• Stick it along the edge of the sled base for easy reference when measuring cuts.

Step 7: Final Adjustments and Testing

Check for Square

• Use a large square to check that the fence is square to the base.
• Make adjustments as necessary.

Test Cuts

• Perform a few test cuts on scrap wood to ensure accuracy and smooth operation.

Conclusion

Building a crosscut sled for your Dewalt DWE7491RS table saw greatly improves cutting precision and efficiency. Remember to use high-quality materials for durability and always check measurements for accuracy. Enjoy the enhanced safety and ease of use in your woodworking projects! For further resources and detailed plans, check out the AllFlavor Workshop website.