A Precise Table Saw from an Electric Hand Saw

Step 11 Cutting a miter slot

The shim from the previous step needs to be rather precise.  Make a test slot on some scrap wood before cutting on your saw table. 

Make one cut with the base of the circular saw riding against the straightedge (first graphic).  Then make a second cut with the shim against the straightedge and the saw riding against the shim (second graphic--The brown piece is the shim.  Note the second cut to the left of the first cut.  Thanks to Google Warehouse for the image of the circular saw.  The image happens to show a left-hand drive saw, although most home circular saws are right-hand drive.).  Make some freehand cuts to remove as much of the waste material between the two cuts as possible.  Make the bottom of the slot smooth with a chisel or a rasp.  Check to see how the steel bar from the miter gauge fits in the slot.  Rub some paraffin in the slot to make the miter gauge slide more easily.

If the shim produces a test slot that is a little too narrow, cover one edge of the shim with a layer or two of black electrical tape and make another pass with the saw.  If the test slot is a little too large, sand or plane the shim to narrow it a little.