This project was built and designed by Jodee from Inspire Woodcraft.
It’s a no-nonsense miter saw stop block setup that’s simple, effective, and easy to build with common materials.
Jodee’s goal was to replace the old tape-and-scrap method with a reliable, adjustable system using t‑track and a beefy stop block. The result is a shop upgrade that boosts accuracy and efficiency without requiring expensive hardware.
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Why a Better Stop Block Matters
A miter saw station is only as good as its repeatability. Jodee explains how using a temporary block with double‑sided tape worked for a while but slowed things down during larger projects.
To solve that, he built a robust stop block that locks into a shallow t‑track groove routed into the workstation surface. The system allows for quick adjustments and dependable stops, making it a huge time-saver for repetitive cuts.
The Core Idea
Jodee’s system focuses on simplicity and reliability. Instead of designing a complex fence or buying a commercial jig, he uses three key elements:
- A shallow t‑track groove routed into the surface
- A tall, solid stop block made from scrap wood
- A sliding key and T‑bolt assembly to lock it in place
With these elements, the stop can be positioned quickly, locked down tightly, and used confidently for batch cuts and dimensional work.
Routing the Groove
The groove is routed using an edge guide to ensure it runs parallel to the fence. Jodee sets the cutting depth so the t‑track sits just below the surface—enough to be flush, but not so deep that it weakens the bench.
This groove keeps the track clean and allows the stop block to slide smoothly without debris buildup. A test fit ensures the track sits tight and level before moving on to installation.
Building the Stop Block
Rather than using a thin scrap of wood, Jodee builds a substantial stop block. The height and width allow for stacking multiple boards and support even thick materials during cuts.
He mills the block to a size that clears the fence and fits well with the miter saw’s range of motion. A separate key is cut to fit inside the t‑track, and the block is designed to align precisely when the key is inserted.
Assembling the Sliding Key
The key is glued into a routed channel on the underside of the stop block. It doesn’t need to be permanent—just strong enough to stay put during use.
Once the adhesive sets, the assembly is test-fit again in the track to ensure it slides freely but doesn’t wobble. This combination gives the stop solid lateral support while keeping it easy to reposition.
Adding the T‑Bolt and Knob
A hole is drilled through the center of the block and key for a T‑bolt to pass through. The bolt locks into the t‑track when tightened with a knob from above.
This allows the stop to be adjusted with one hand and secured in seconds. It’s a simple mechanism that adds a lot of speed to repetitive cutting tasks without sacrificing precision.
Trimming for Blade Clearance
During testing, Jodee realizes the stop block interferes slightly with the saw arm. To fix this, he trims one edge at an angle so it clears the blade housing.
This minor adjustment allows the stop to be used on either side of the saw and avoids needing a mirrored version. It’s a smart fix that improves usability without altering the core design.
Chamfering and Finishing Touches
Both ends of the block are chamfered to prevent sawdust from accumulating underneath. This keeps the stop seating flush and helps maintain accurate cuts.
Edges are softened for comfort, and a dark stain is applied to make the stop block stand out from regular scrap pieces. This helps prevent it from getting lost or accidentally tossed in the bin.
Performance and Optional Tweaks
The finished stop block performs well in daily use. It’s solid, stays put, and supports batch cutting jobs with ease. The extra height helps when cutting thicker materials, and the face provides plenty of surface area for contact.
While the current setup is highly functional, Jodee mentions a few possible upgrades:
- Adding a measuring scale for faster adjustments
- Using sacrificial face strips to extend the life of the block
- Installing a micro-adjust feature for ultra-precise stops
But even without these additions, the base version offers a huge improvement over temporary setups.
Tips and Lessons from the Build
Jodee shares a few key lessons learned:
- Always test fit your t‑track and key before final glue-up
- Make your block taller and wider than you think you’ll need
- Add sawdust relief to avoid shifting during cuts
- Color-code shop jigs so they don’t get lost or mistaken for scraps
These little tips help improve the longevity and usability of your stop block and make shop life just a bit smoother.
A Shop Upgrade Worth Doing
For any woodworker looking to increase speed and accuracy at the miter saw, this stop block setup is worth replicating. It’s affordable, easy to build, and solves one of the most common frustrations in repetitive cutting.
Jodee’s straightforward approach proves you don’t need expensive gear to work smarter. A few pieces of wood, a t‑track, and some thoughtful design can lead to a major workflow upgrade.
Support Jodee by visiting his online store here: https://inspirewoodcraft.com/collections/all.