After having a little bit of trouble crosscutting anything wider than about 7″ on my tablesaw I decided that I needed a crosscut sled. Rather than spending over $100 to buy one I decided to make one myself using a 2’x4′ sheet of MDF and a 5/4″ thick stair step. Total cost for the build was under 25 bucks.
I didn’t do a very good job taking pictures of the first part of the build, so I’ll do by best to describe the process with text.
The first thing I did was cut two 3/4″ slices from the end of the MDF to use as runners for the sled. Then I cut a 16″ piece from the MDF using a circular saw. This cut didn’t need to be exact (or even straight) since it would be trimmed later. At this point I had the two halves of the sled. On each half I cut a 3/4″ wide 3/8″ deep dado to hold the runner. I screwed the runner down from the top of the sled making sure that the tops of the screws were below the surface of the MDF. Finally I ran each half of the sled through the table saw using the runner as a guide, leaving me with two properly sized sections as seen below.