In the photo you see my rip guide prepared to trim 1/8 inch from the bottom of a door.
Step 1: Materials and tools
- 1 MDF trim board 3/4 x 3 1/2 x 96 inches
- Tempered Masonite 3/16 x 15+ x 96 inches
- Bevel-headed wood or sheet metal screws: # 8 x 3/4 inch
- Drill with bit and countersink
Have the store rip 15 or 16 inches from the long side of a sheet of 4 x 8 feet Masonite. It does not matter if the cut is not completely straight, but the panel saw will likely yield a straight cut. (My saw's base is wider than some with almost exactly 5 inches between the edge of the base under the motor housing to the nearest side of the saw blade. If your saw's base is smaller, the Masonite could be narrower. But, the Masonite needs to be twice as wide as the base dimension on the motor side of the base plus the width of the trim board. Leave a little extra on both sides to be trimmed away.)
I had a car, not a truck, when I went to the store. I had the store cut the remainder of the Masonite so I had two pieces about 33 x 48 inches each. They may not go into a car trunk, but will slide through a rear car door and not rise above the seats to obstruct your rear view on the way home. (The panel saw at my store is poorly aligned and corners on crosscuts are not square. The operator has tried several times to get the management have the saw aligned again, but has been unsuccessful. Be aware.)
Plans for rip guides like this often suggest ripping about 6 or 8 inches from the long side of a sheet of 1/2 inch plywood. This is aligned along the edge of a sheet of Masonite. That means you may be buying both a sheet of plywood and a sheet of Masonite. One advantage to my version is that you buy a sheet of Masonite and a trim board only, which makes for a lower cost. (Also, if you are cutting the piece that will actually guide the saw, you will need a means of guaranteeing that cut is perfectly straight. That may not be possible in a beginner home workshop. The straight trim board will be a big advantage for getting a straight guide without a large table saw the beginner workshop may not have.)
Center the trim board on the long Masonite piece and clamp with "C" clamps. Support this sandwich with enough sawhorses to keep it from bowing.