Jodee from Inspire Woodcraft shared the woodworking project featured in this video.
The video demonstrates a simple crosscut sled designed to eliminate kickback and make repeatable small-part cuts safe and efficient.
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Design & Purpose
The sled is built around two core ideas: keep offcuts from being pinched between the blade and the stop, and stop small pieces from piling and vibrating beside the blade. Jodee solves both issues with a two-layer base and a beveled, replaceable insert that funnels scrap away from the cut.
The overall design stays intentionally simple so it’s easy to build, service, and adapt for different saw setups. The sled also works with a single miter bar and can be positioned to run in either miter slot for flexibility.
Materials & Layout
Materials are minimal and practical: plywood for the base and fences, a denser wood for durable stop blocks, thin smooth sheet material for the sliding face, and inexpensive jig hardware for the stop system.
Jodee prefers a hardwood for longevity on the contact faces but notes that plywood or other woods can be used depending on availability and wear expectations.
Layout relies on simple shop fixtures rather than complex measuring, with the fence used as a reference during glue-up to keep parts flush and square. Double-sided tape and small screws are used strategically to hold the replaceable insert and miter-bar hardware in place.
Assembly & Miter Bar Setup
Assembly focuses on speed and reliability: wood glue is applied for long-term strength and cyanoacrylate with accelerator is used as a temporary clamp to hold pieces while the glue cures. Countersunk pilot holes and a careful screw layout avoid placing hardware in the blade’s path.
Jodee reuses an adjustable miter bar for a smooth, adjustable fit and aligns the sled to the saw using the fence for squaring. The method is practical for someone who trusts their saw’s setup; those with less-trued machines may want to square the sled with measuring tools instead.
Replaceable Bevel Insert & Debris Control
The key innovation is the beveled secondary base that sits bevel-up just past the blade and guides offcuts away from the kerf. That replaceable piece prevents tiny scraps from getting pinched and reduces the build-up of vibrating debris beside the blade.
Because the insert is removable and mechanically fastened, it can be replaced if the kerf widens over time or if it becomes damaged. This approach extends the sled’s usable life without forcing a full rebuild.
T-Track, Stop Blocks & Repeatability
A short length of T-track on the front fence accepts a two-part stop system that produces repeatable cuts without ever letting a piece sit between the blade and a fixed block. The system uses a non-sliding block as a reference and a sliding block that locks against it, so the final stop position is always set off the blade.
The sliding face for the handhold is thin and low-profile to keep the operator’s hand comfortable during repeated cuts, and a micro-adjust option can be added by screwing into a stop block for fine tuning. Jodee also points out that a clamp-based stop is possible, but some may find it slower to reposition for repetitive work.
Using the Sled: Operation & Safety
Operation is straightforward: set a ruler to the desired distance from the blade, position the sliding stop against the ruler and then lock the primary stop against the sliding stop, then feed the part with hands clear of the blade. Because the stop stack sits off the blade and the beveled insert funnels scrap away, there’s little risk of pinch-induced kickback or scrap accumulation.
The sled keeps the operator’s hands well away from danger and allows fast, repeatable throughput for small parts. It’s a practical upgrade for anyone who frequently cuts short pieces and wants a safer, more predictable workflow.
Tips, Variations & Adaptations
Jodee offers several adaptable choices: use different stop materials depending on wear needs, swap the thin sliding face for other low-friction sheet goods, or add a micro-adjust screw to a stop block for fine-tuning. The replaceable insert concept also lets makers experiment with material, bevel angle, or height to match their parts.
The sled can be adapted to different table saws and preferred workflows; users can choose to add a second miter bar, change fastener layout, or install a longer T-track for additional fixturing. The core idea—keeping offcuts away from the blade and stops off the kerf—remains useful across setups.
Why This Matters
This sled addresses two common and dangerous problems when cutting small parts: pinch kickbacks and scrap buildup.
By combining a replaceable beveled insert, an off-kerf stop stack, and a simple miter-bar mounting method, the design makes small cuts safer and more consistent.
The approach is accessible, low-cost, and adaptable, making it a valuable addition to a home or small shop where small-part repeatability and safety are priorities. Builders can tweak materials and details to suit their tools and preferred workflow.
Support Jodee by visiting his online store here: https://inspirewoodcraft.com/collections/all.