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18th August 2008, 12:21 PM #1
Jig for cutting sheets with a handheld saw or router.
I saw this idea a while back & have been talking about making it for a while.
It is a guide for cutting/trimming long edges on sheet material.
Basically just a bit of thin MDF glued to an Ali straight edge.
You order a 6M length of Ali & ask for 1.2M to be cut off the end & then have the remaining bit cut in half, 2 x 2.4M.
Then scrounge an MDF packing sheet from the local hardware shop.
Mark out & glue the Ali to it & then cut it out.
The pictures tell the story.
I have a big old lump of veneered chipboard (also scrounged) that I throw on top of my trailer as a work surface & now I have jigs for cutting across or along sheet material.
Last pic shows the finished jigs & a transport case for some Bessy clamps.
I made it out of the rest of the MDF packing sheet & some strips of hardwood.Cliff.
If you find a post of mine that is missing a pic that you'd like to see, let me know & I'll see if I can find a copy.
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18th August 2008, 02:49 PM #2Skwair2rownd
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Bugger! someone pinched my method!
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18th August 2008, 02:59 PM #3
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18th August 2008, 09:06 PM #4GOLD MEMBER
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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.
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18th August 2008, 11:00 PM #5
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.
JoeOf course truth is stranger than fiction.
Fiction has to make sense. - Mark Twain
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18th August 2008, 11:08 PM #6Cliff.
If you find a post of mine that is missing a pic that you'd like to see, let me know & I'll see if I can find a copy.
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18th August 2008, 11:37 PM #7
Thanks.... I'd rather have a table saw that will handle sheets but this works for me.
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.
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.
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.
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.
Yup, me too.
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.Cliff.
If you find a post of mine that is missing a pic that you'd like to see, let me know & I'll see if I can find a copy.
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18th August 2008, 11:54 PM #8
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18th August 2008, 11:56 PM #9
Don't wait by the post box holding yer breath DJ.
Cliff.
If you find a post of mine that is missing a pic that you'd like to see, let me know & I'll see if I can find a copy.
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21st August 2018, 10:08 PM #10
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.jpgCliff.
If you find a post of mine that is missing a pic that you'd like to see, let me know & I'll see if I can find a copy.
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