I'm planning to make a large(r) crosscut sled so I can cut 24" pieces (the size of the hinged lids for my drop zone).
The first thing I realised is that without an existing large crosscut sled, it's difficult to get a perfectly square piece of plywood for the base for the new one.
I had to use a combination of the table saw and circular saw, coupled with a large square and straight edge (which I first had to make on the table saw ... :icon_scra).
Anyway, the base is done and then I moved on to the fences.
I'm using 3/4" plywood - two pieces laminated together.
I can't use hardwood as I don't have a jointer and planer to ensure a perfectly flat face.
Unfortunately, the plywood is bowed and although I put the two bowed sections together opposite (to cancel out the bow), it's still not perfectly flat.
So, what are my options considering my limited tools?
I even considered some sort of aluminium straight edge as the rear fence but there are obvious issues with that with regards to cutting the slot, possibly catching the blade with it, etc.
The first thing I realised is that without an existing large crosscut sled, it's difficult to get a perfectly square piece of plywood for the base for the new one.
I had to use a combination of the table saw and circular saw, coupled with a large square and straight edge (which I first had to make on the table saw ... :icon_scra).
Anyway, the base is done and then I moved on to the fences.
I'm using 3/4" plywood - two pieces laminated together.
I can't use hardwood as I don't have a jointer and planer to ensure a perfectly flat face.
Unfortunately, the plywood is bowed and although I put the two bowed sections together opposite (to cancel out the bow), it's still not perfectly flat.
So, what are my options considering my limited tools?
I even considered some sort of aluminium straight edge as the rear fence but there are obvious issues with that with regards to cutting the slot, possibly catching the blade with it, etc.