Looking for a critique from experienced users before I build my first frame. I want to be able to use the full 4’x8’ cutting area, so I will build in skirting. I was thinking of a way to make the skirting adjustable to different thickness cutting materials, which has some challenges and adds to the setup time, but then I thought instead to have the skirt height fixed and adjust my cutting material to be flush with the skirt.
For my frame I plan to use plywood or MDF permanently mounted, mainly to stiffen the frame, then a spoil board over top of this, then my cutting material. For the spoil board I like the idea of XPS foam, because it’s cheap and lightweight (although messy when cut). It is also readily available in different thicknesses (I hope foam dimensions are pretty true?), so by keeping a few different foam boards on hand I can cut different thickness woods easily and always keep the wood flush to the skirt.
1/4” spoil board + 1” cutting material
1/2” spoil board + 3/4” cutting material
3/4” spoil board + 1/2” cutting material
1” spoil board + 1/4” cutting material
My only concern is the foam or cutting material being bowed and not aligning with the skirt well. But maybe the weight of the sled will help keep it flat where cutting?
Any thoughts on this project?