**INFINITY CUTTING TOOLS TCS-200 Professional Crosscut Sled Instruction Manual

**

ASSEMBLY INSTRUCTION

Congratulations on purchasing your new Infinity Tools Crosscut Sled, TCS-200. This sled is CNC machined for exacting tolerances with two cutting positions allowing you to make accurate crosscuts and bevel cuts up to 12” wide. Because of its unique replaceable ZCI design, this sled can even be used to make dado cuts, and then be converted back for traditional crosscut work. This sled is designed to work with table saws with standard 3/4” x 3/8” miter tracks 4-½” to 7-½” measured from the center of the track to the saw blade.

Parts List

A. Sled Base, 1x
B. 4” Rear Fence, 1x
C. 3-¼” Front Fence, 1x
D. 3” Fence Face, 1x
E. Handle, 1x
F. Aluminum Rail, 1x
G. Zero Clearance Insert, 2x
H. Safety Visor, 1x
I. #8 x 1-½” long flat head wood screws, 16x
J. #6 x 3/4” round head wood screws, 4x
K. Brass washers, 4x
L. 8-32 threaded inserts, 12x
M. 8-32 x ½” flat head screws, 12x
N. ¼-20 x 2” flat head screws, 3x
O. ¼” oversized washers, 3x
P. ¼-20 wing nuts, 3x
Q. ¼-20 x 2” hex bolts, 2x
R. ¼-20 Star knobs, 2x
S. Miter Bar
T. Hold-down Clamp Kit (not pictured)
U. Infinity Nameplate, 1x
V. #4 x ½” flat head wood screws, 2x

Required tools

• 5-32”: Allen Wrench

• 2 Phillips Screwdriver

Assembly

Step 1. Install the 12x threaded inserts (L) into the pre drilled and countersunk holes in the bottom of the sled base (A). Step 2. Install the 4” tall rear fence (B) into one of the slots in the sled base (A) using 6x #8 x 1-½” wood screws (I). Ensure the pre-drilled pilot holes are properly aligned. Ensure the microdot surface of the 4” fence faces inward.

Note , the sled base is symmetrical, either slot can be used.

Step 3, Install the 3-¼” Front Fence (C) into the other slot on the sled base (A) using 6x #8 x 1-½” wood screws (I). Ensure the pre-drilled pilot holes are properly aligned. Ensure the microdot surface of the 3-¼” front fence faces outward.

Note on Installing Front and Rear Fences (Steps 2 and 3 above): Our TCS-200 base is CNC machined, allowing for precision right out of the box, without the need for test cuts or further calibration. Due to the tight tolerances of our machining process, you may find it a very snug fit when installing front and rear fences into their corresponding slots. If you run into difficulty pressing the fences into place with your hands alone, we recommend placing a wooden block on the top edge of the fence (before installing the top rail) and tapping it into place with a mallet. Alternatively, you might use a trigger-style clamp or another type of press mechanism.

Step 4. Install the Handle (E) onto the 3-¼” front Fence (C) using 2x 6x

8 x 1-½” wood screws (I).

Step 5. Install the Zero Clearance Inserts (G) into the Sled Base (A) using 12x 8-32 x ½” flat head screws (M)

Step 6. Install the Fence Face (D) onto the 3-¼” front fence (C) using 3x ¼-20 x 2” flat head screws (N) ¼” oversized washers (O), and ¼-20 wing nuts (P)

Step 7. Install the Aluminum Rail (F) onto the 3-¼” front fence (C) using 4x

6 x 3/4” round head wood screws (J) and Brass washers (K). Align the front

edge of the Aluminum track with the face of the 3” fence face and tighten the mounting screws.

Step 8. Install the Miter Bar (S) into the slot on the bottom of the Sled base (A) Using 2x #8 x 1-½” long flat head wood screws (I)

Step 9. Install the Safety Visor (H) onto the Aluminum rail using 2x ¼-20 x 2” hex bolts (Q) and Star Knobs (R). The visor will bridge from the front to rear fences and extends past the front fence to protect against accidental contact with the saw blade on the exit of cuts.

Step 10. Install the Infinity Nameplate (U) into the machined pocket in the sled base (A) using 2x #6 x ½” flat head wood screws (V)

Step 11. Assemble the Hold-down Clamp Kit and install onto the aluminum rail (F) if desired.

Confirm fitment of 90° cuts for left and right tilt saws.

Note. Failure to follow the instructions below before making a cut can result in damage to your crosscut sled, blade, table saw, may cause personal injury, and will void any warranty.

Follow these simple steps to check any sawblade type for all 90° cuts. Because the distance from the saw blade to the miter tracks varies depending on saw brand/model and blade kerf, it is important to confirm that the blade being used will pass through the ZCI without interference. To do this,

Install your desired blade and set to 90°.

1. 2. Measure from the inside edge of the blade to the center of the left miter track. The measurement must be 4-½” or greater.
2. Measure from the outside edge of the blade to the center of the left miter track, this measurement must be 7-½” or less.
3.  If yes to both 2 and 3 you can make a cut with the installed blade/dado stack using the sled in the left miter track.

Confirm fitment for 45° bevel cuts.

1. Because the saw blade tilts closer to or further from the miter slots when tilted, it is important to check for proper clearance before making a bevel cut. Follow the instructions for either left tilt or right tilt saws below.
2. For left tilt saws (The top of the blade tilts toward the left miter slot)
3. Install your desired blade and tilt to 45°
4. Measure from the inside edge of the blade to the center of the left miter track. The measurement must be 5-1/4” or greater.
5. Measure from the outside edge of the blade to the center of the left miter slot. The measurement must be 7-½” or less.
6. If yes to both 4 and 5 you can make a cut with the installed blade/dado stack tilted to any angle using the sled in the left miter track.
7. Measure from the Inside edge of the blade to the center of the right miter slot. The measurement must the 4-½” or greater.
8. Measure from the outside edge of the blade to the center of the right miter slot. The total must be 6-3/4” or less.
9. If yes to both 7 and 8 you can make a cut with the installed blade/dado stack tilted to any angle using the sled in the right miter slot.

For Right Tilt Saws (The top of the blade tilts toward the right miter slot)

1.  Install your desired blade and tilt to 45°
2. Measure from the inside edge of the blade to the center of the left miter track. The measurement must be 4-1/2” or greater.
3. Measure from the outside edge of the blade to the center of the left miter slot. The measurement must be 6-3/4” or less.
4. If yes to both 2 and 3 you can make a cut with the installed blade/dado stack tilted to any angle using the sled in the left miter track.
5. Measure from the Inside edge of the blade to the center of the right miter slot. The measurement must the 5-1/4” or greater.
6. Measure from the outside edge of the blade to the center of the right miter slot. The total must be 7-1/2” or less.
7. If yes to both 5 and 6 You can make a cut with the installed blade/dado stack tilted to any angle using the sled in the right miter slot.

References

• Infinity Cutting Tools

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