In this Instructables I will show videos building a replacement mitre saw base. In the first video I make design and cut the base which includes positive stops. The second video I install a fence and the angle locking mechanism, and in the final video I make a zero clearance insert, scribe the angle increments, and make a dust deflection baffle.

Step 1: Design, CNC'd Parts and Positive Stops

In this part I make a pivoting base or stand to mount the head of a cheap Mitre Saw, with the usual positive stops.

00:02 Introducing the build.
01:14 Cutting a miniature maquette / prototype.
02:03 Testing fit of pieces.
02:35 Making the positive stop.
04:42 The pieces in birch ply.
05:22 Adding ball catch.
06:27 Installing saw motor.
07:29 Re-installing saw motor.
08:09 Fence positioning
08:50 A natural end.

Step 2: Fence and Angle Locking Mechanism

00:19 Planing the location of the fence.
00:32 Screwing the base to the turning collar.
01:10 Cutting fence pieces.
01:30 Double checking line.
01:57 Gluing fence pieces together.
02:33 Drilling and screwing fence to base.
04:48 Fitting rubber feat to base.
04:55 Making locking handle.
07:22 It worked.

Step 3: Zero Clearance Insert, Dust Flange and Increments

I don't talk much in this one, so these time codes might be more important.

00:05 It's a bit stiff, I should sort that out later.
00:26 Checking how accurate my angles are. Seems good enough.
01:11 I use this flush trim bit to router a channel around the edge of the base, so dust can fall.
02:08 CNC'ing the female part of the zero clearance insert.
03:11 CNC'ing the male part of the insert plate.
04:42 This insert is a little shallow, but that is not a problem.
06:26 Extraction and making the dust baffle.
07:40 I missed a stage - mere mortal.
08:40 Cutting the rubber flange.
09:27 TEST CUT
09:44 Increments
10:18 Using a razor to smooth the paint job - which I done off screen.
11:33 Final Thoughts.