I built the “Ultimate Crosscut Sled” featured in AW #75 (October 1999).
It works great, and recently I've added an adjustable stop, which makes
it even better. I thought other AW readers would be interested in my
upgrade. My 50-in.-capacity stop consists of scrap wood, a 48-in.
T-track (I used Mini Track from www.prairieriverwoodworking.com),
1/4-20 hex-head bolts and a couple of plastic knobs. I spent less than
$25. My stop makes repetitive crosscutting of long stock—shelves for a
bookcase, for instance—a breeze. Any hardwood will do for the rail and
stop; I used a 7/8-in. x 2-in. x 60-in. piece of hickory. You can
increase the crosscut capacity by using a longer rail. I cut a stopped
dado in the back of the rail to house the T-track, which I installed
with screws. I attached the stop to the end of the rail with a glued
half-lap joint. I counterbored a pair of holes in the sled's fence and
installed the bolts and knobs.
T-track makes the stop easy to install and adjust. When the stop
isn't necessary, tightening the knobs draws the bolts into the
counterbored holes, so they don't protrude.