As most of you know, I like to use a bunch of pins in my handle design. I wanted something unique and distinctive for my handles. I came up with a pattern that uses 7 pins in the handle. Well, cutting all those pins was always a chore, and I did not have a very safe way to do it.
One day I had an idea pop into my head while cutting a lot of pins. What if I made a cross cut sled that fits in the slots here on the SWAG table for my portaband! Well a couple hours later, some scrap plywood, and a mess of wood glue, my idea came to life. It has worked really well for me processing the pins and tubing I use on my handle designs.
I tagged SWAG Offroad in one of my Instagram posts using the sled and the response this time was very big. It seemed a lot of people were having the same problem as me when cutting their pins for knifemaking. This little 3D printed sled helps with all of that! It is recommended to mount this cross sled to a fixture so that twisting can not occur while using it. The 3D printed component is designed to be used with #8 flat head screws wood screws (82° under the head). If you order the printed model, four mounting screws (1/2″ long) will be included.
There are three inserts (1/4″, 1/2″, 3/4″) to vary the gage length of the sled. Select the appropriate length you want the pins and insert your pin stock. Push the end of the pin so it is flush, holding the excess pin material, push the sled so the bandsaw blade cuts only the pin material. I have found to get a little bit cleaner of a cut, I can rotate the pin material while cutting to get less of a burr at the end. Pushing slowly also helps with this, allowing the blade to do more cutting than tearing.
The inserts have sizes that are slightly larger than the pin material too make inserting easier.
- Ø1/16″ → Ø0.073″
- Ø1/8″ → Ø0.135″
- Ø3/16″ → Ø0.198″
- Ø1/4″ → Ø0.260″
- Ø5/16″ → Ø0.323″
- Ø3/8″ → Ø0.385″
- Ø1/2″ → Ø0.510″
The main sled body is 5.5″ by 4″ and is 1.125″ tall. For the Digital STL files, there are 2 body files where one is 3.5″ wide to fit on more printers (Resin printers) that have a smaller print area.
Slicer Critical Information (These settings have worked well for me)
- Infill Density: 15%
- Infill Pattern: Gyroid
- Perimeters: 2
- Top / Bottom Fill Pattern: Monotonic
- Layer Height: 0.15mm
- First Layer Height: 0.2mm
When using this product:
- Wear Appropriate Safety Gear: Prior to using the Cross Cut Sled, ensure you are wearing appropriate safety gear, including safety glasses, hearing protection, and any other necessary personal protective equipment (PPE).
- Secure Workpiece: Always ensure your workpiece is securely clamped or held in place to prevent movement during cutting. Unstable or improperly secured materials can lead to accidents.
- Maintain a Safe Work Environment: Operate the Cross Cut Sled in a clean, well-lit, and organized workspace. Remove any obstacles or debris that may interfere with the operation of the equipment.
- Keep Hands Away from Moving Parts: Never place your hands or any body part near the moving blade or the sled’s cutting path. Maintain a safe distance from all moving components during operation.
- Turn Off Power When Not in Use: When not actively cutting, turn off the power to your portable band saw and ensure it comes to a complete stop before making any adjustments, maintenance, or blade changes.
- Inspect the Sled Regularly: Before each use, inspect the Cross Cut Sled for any signs of wear, damage, or loose components. Do not use the sled if you identify any issues; instead, address them promptly.
- Keep Out of Reach of Children: Store the Cross Cut Sled in a secure location, inaccessible to children and unauthorized users. This product is not intended for use by minors.
- Use Only as Intended: The Cross Cut Sled is designed for specific cutting applications as described in its product description. Do not use it for any other purposes or with incompatible materials.
- Seek Professional Assistance: If you encounter any issues with the installation, operation, or maintenance of the Cross Cut Sled that you are unsure how to resolve, seek professional assistance from qualified technicians or contact the manufacturer.
Remember that safety is your responsibility. Following these safety guidelines and exercising caution while using the Cross Cut Sled will help minimize the risk of accidents and ensure a safe and productive work environment.