Furnished content.
(from Lumberjocks.com)
I finally got tired of having to use my large heavy sled for all my crosscut requirements so I finally built myself a sled, that will still handle almost all my crosscut needs, and is both light weight and smaller as well.The sled's base is made from 1/2 birch plywood measuring 24 L x 14 W with one of the corners trimmed off and nine 2 diameter holes to reduce the overall weight of the base. For the fence I used a piece of 1.5 x 1.5 aluminum angle to match the length of the base with a cut-out to clear the saw blade. To attach the fence to the base I used a couple of studded knobs which fit into T-nuts that rest in counterbores cut into the bottom of the base. To fancy things up a little I used black walnut to make both the front fence and the table saw blade guard. I added a small adjustable locking stop block which allows me to make multiple cuts of identical length with ease.For a finish I applied three coats of gloss polyurethane sanding between each of the coats.