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:

1. I cut an old piece of 2×4 to length.
2. Using the jointer, I flattened the front face and squared the bottom.
3. I also cleaned up the top and back on the jointer.
4. 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.
5. All of the top, left, and right face edges also got the chamfer for comfort when handling the sled.
6. I went over all of the chamfers with a sanding block.
7. 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.