So I'll be making a crosscut sled soon and am wondering if I should make the fence out of ply or hardwood. I don't have a jointer to run a hardwood board through, so would a couple of pieces of ply glued together be a good option?
I don't like the edge of plywood showing on jigs. Actually my sled has 3 separate fences. Two of them are adjustable and are ahead of the front fence which is structural. There's a gap between the adjustable fences where the saw blade goes after the cut.
However, you can make a sled with the blade extending towards the operator after the cut OR the blade does not extend out towards the operator, which I prefer for safety reasons like this:
I used a laminated plywood fence for many years with this router table. Extremely stable and stiff. I remember squaring the face on the tablesaw. Only pic I have, the fence is at the front. Your fence wouldn't need to be this wide. However, all my sleds have hardwood fences.
You should be fine either way, just don't stand a piece of plywood on edge and expect it to remain straight and stable!
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