Thread: Jig for cutting sheets with a handheld saw or router.

Bugger! someone pinched my method!

Originally Posted by artme

Bugger! someone pinched my method!

I pinched it from somebody else.

Main trouble I have found with this type of guide is that the saw can wander away from the guide towards the end of the cut - in the middle of an 8x4 it is very hard to apply side pressure to keep it against the fence.

Good setup, Cliff.

Without doing the maths, I'd be tempted to add some CSK FH self-tapping screws from the bottom into the Al to maximise transverse stiffness of the combination. A glue with "flex" in the name doesn't give me enough confidence.

Pics: (Sheets 011) and (Sheets 013) look like you make the final cuts with the saw, all well and good; similar for the cuts with the router. But (Sheets 017) looks like a hybrid board for both the saw and the router. Something not registering for me there. Also, is the router base marked which side is which? Hard to believe the cutter is perfectly centred; luckily, my Ryobi has only one flat side.

For cutting cross-wise on an 8x4, it might not hurt to stop mid-course and continue the cut from the other side. Or have I misunderstood that too?

Except for mating re-cuts along imperfect joins, I generally use only the wider part of the saw's foot plate against a straightedge.

Nice case for the clamps, too. I guess it has a hinged door with latch at the far end? The pic didn't reach that far.

Joe

Originally Posted by bsrlee

Main trouble I have found with this type of guide is that the saw can wander away from the guide towards the end of the cut - in the middle of an 8x4 it is very hard to apply side pressure to keep it against the fence.

Remember that 2nd bit of Ali?

Clamp it to the sheet on the outside of the saw sole.... just use the sole to set the space at each end before you start.

Originally Posted by joe greiner

Good setup, Cliff.

Thanks.... I'd rather have a table saw that will handle sheets but this works for me.

Originally Posted by joe greiner

...I'd be tempted to add some CSK FH self-tapping screws from the bottom into the Al to maximise transverse stiffness of the combination. A glue with "flex" in the name doesn't give me enough confidence.

It is a 2" wide bit of Ali, it doesn't move very far over the 8' length.
The MDF finished up at about a foot wide so it doesn't flex at all across its width.
It does flex a bit up & down so the flexible glue will stop it from popping off.
The up down flex doesn't matter 'cos it will be supported by the sheet to be cut.

Originally Posted by joe greiner

Pics: (Sheets 011) and (Sheets 013) look like you make the final cuts with the saw, all well and good; similar for the cuts with the router. But (Sheets 017) looks like a hybrid board for both the saw and the router.

Yup, sorry, there was an extra picture but I dropped it out 'cos I thought I was overdoing it.
Sheets 011 shows me trimming the saw side of the 8' (2400mm) piece.
If you look back at Sheets 009, you will see there is a wide squiggly red line between the 8' piece & the 4' piece. The line allows for a 1/2" error & I cut it by eye in Sheets 013 & then trimmed the saw side of the 4' piece in Pic Sheets 014.

Originally Posted by joe greiner

Something not registering for me there. Also, is the router base marked which side is which? Hard to believe the cutter is perfectly centred; luckily, my Ryobi has only one flat side.

Each piece has a saw side & a router side. (See pic Sheets 017)
I only ever cut with the wide side of the saw sole againts the Ali as this gives more support.
The router has 2 flat sides but I always grip it the same way so I can operate the power switch with my right thumb.

Originally Posted by joe greiner

For cutting cross-wise on an 8x4, it might not hurt to stop mid-course and continue the cut from the other side. Or have I misunderstood that too?

I have long arms... I come from Longreach (Place in Queensland )
See my post about clamping the spare bit of Ali on as a 2nd guide on the other side of the saw.

Originally Posted by joe greiner

Except for mating re-cuts along imperfect joins, I generally use only the wider part of the saw's foot plate against a straightedge.

Yup, me too.

Originally Posted by joe greiner

Nice case for the clamps, too. I guess it has a hinged door with latch at the far end? The pic didn't reach that far.

It is just a shipping case, fairly rough up close, it wouldn't win a prize in the box making comp. It just has to be strong & light.
There 6 Bessy clamps going in it on a long plane ride tomorrow morning.
Once it arrives, the new owner can save the handles & feed the box to the bonfire.

Originally Posted by Cliff Rogers

It is just a shipping case, fairly rough up close, it wouldn't win a prize in the box making comp. It just has to be strong & light.
There 6 Bessy clamps going in it on a long plane ride tomorrow morning.
Once it arrives, the new owner can save the handles & feed the box to the bonfire.

Geeze thanks Cliff, you didn't have to pack them that well, but it's appreciated. I'll put the handles to good use

Don't wait by the post box holding yer breath DJ.

Pictures have all gone missing, here they are again.
Sheets 001.jpgSheets 004.jpgSheets 005.jpgSheets 006.jpgSheets 007.jpgSheets 008.jpgSheets 009.jpgSheets 010.jpgSheets 011.jpgSheets 013.jpg