Table Saw Crosscut Sled — board plan

What to buy, and which parts come off which board.

Buy 3 boards at 8 ft.

1 1/2" × 3 1/2" — Maple

1 board · 2.3 board feet (includes 15% for knots and defects) · 58% of the boards you buy used

Board 1 · 40 3/4" left over
27"27"
1. Rear fence (the important one) — 27"
2. Front fence — 27"

1/2" × 27" — Baltic Birch Plywood

1 board · 2.2 board feet (includes 15% for knots and defects) · 22% of the boards you buy used

Board 1 · 74 7/8" left over
20"
1. Sled base — 20"

3/8" × 3/4" — Maple or UHMW

1 board · 0.1 board feet (includes 15% for knots and defects) · 51% of the boards you buy used

Board 1 · 46 3/4" left over
24"24"
1. Runners — 24"
2. Runners — 24"

Cuts are listed longest-first, which is how they should be made: the awkward pieces get placed while there is still board to place them on. The layout assumes one end of each board is squared off (1") and that every cut costs 1/8" of kerf — the reason six 16″ parts do not fit on a 96″ board.

1 1/2" × 3 1/2" — Maple

Board 1 · 40 3/4" left over

1/2" × 27" — Baltic Birch Plywood

Board 1 · 74 7/8" left over

3/8" × 3/4" — Maple or UHMW

Board 1 · 46 3/4" left over