I built my crosscut sled for the table saw just over a year ago and one thing always bugged me. The piece of plywood I used for the original fence had a slight bow to it, so the cuts weren’t perfectly square. While it had served me fine for building shop furniture, it wasn’t going to work when building a couple of cabinets.
To fix the problem:
- I cut an old piece of 2×4 to length.
- Using the jointer, I flattened the front face and squared the bottom.
- I also cleaned up the top and back on the jointer.
- On the router table I added a chamfer to the bottom edge of the front face. It gives sawdust a place to go instead of getting in the way of the work piece.
- All of the top, left, and right face edges also got the chamfer for comfort when handling the sled.
- I went over all of the chamfers with a sanding block.
- Then I attached the new fence to the sled, making sure it was square to the blade slot.
I should have fixed it a long time ago, especially since it was only a 30 minute job.