In this Instructables I will be making a track saw guide. This guide is very stable and extremely accurate. You too can have the same experience, if done right. Hopefully my instructions are clear and easy to follow. Please for give me for any typos. Enjoy :)
Check out the video for a more in depth take
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Step 1: Getting Started
Tools I used for this build
- A router
- A Tape measure
- Combination Square
- Circular saw
1st thing Line the saw up on the plywood. Then mark a line along the base of the saw, on the end that's the furthest from the blade. Measure the line from the edge of the plywood to the mark that was just made. Carry that same measurement the distance of the plywood.
Take a straight object to make a straight line. In my case I used a Aluminum tubing. Now trace the line from end (Im still referring to the very 1st line from the edge of the saw base)
Next move your straight object (aluminum tubing). Now measure from the router bit to the end of the router base. That's the distance you want to set your straight object from the line that I drew out first.
Since im working a 8ft section I place a piece of wood in the center of the tubing to resist flexing.
Step 2: Routing the First Track
Set the router bit to take approx an 1/8th of an inch at each pass. Do this multiple time to achieve the depth of the bar you are using for the track.
Step 3: Marking the 2nd Track
Find a location on your saw for the placement of the second track. Then transfer that to the plywood.
Step 4: Routing the Second Track
Just the like first track use your straight object to help guide the router to make the second router cut.
Now the two bars should move freely in the track. If there is any tension take sander paper and lightly sand the track out.
Also add some wax to help with the friction.
Step 5: Adding the Bars to the Circular Saw
The bars im using was salvage from an audio video rack. You can go to your local hardware store to find bars to attach to your circular saw. I would suggest bars with the minimum of 1/8th thickness.I drill and tap the hole all the way though both the saw base and bar. Then counter sink the hole for the screw head.
Now add the second track. Its real important to maintain the same gap between the tracks. If you fail to do so you will have tension with the slide of the saw.
Then cut off the track at the end of the saw base.
Step 6: Cut Off the Track
Now cut the track off from the plywood.
I also attached a piece of wood to end of the saw track. This should help with lining up the track on to the work surface. This piece was glues and screw in place. Then cut off the overhang .
Step 7: Extra
At the point the track is done.
I don't feel what im doing is necessary but I wanted to experiment. I used Aluminum tape. This only made it look cool. I can't say it made a huge difference.
Step 8: Making the First Cut.
Clamp the track down and make the first pass through.