Introduction: MAX CUT 2 Circular Saw Crosscut & Miter Jig

Picture of MAX CUT 2 Circular Saw Crosscut & Miter Jig

I have this new Jig I recently built and I thought it was a unique jig to have in the shop. I kinda wish I had this years ago when I first started experimenting with wood. I decide to give this jig a name I didn't put much thought into it at all. The first thing that came in my head was Max Cut. I named it MAX CUT 2 because I recently build one which could have used some improvement. In this Instructables I want to share the MAX CUT 2. If your a visual person like my self I have a video as well that goes into greater details. Im working on a limited tools series for the viewers on youtube to get them started. This jig is apart of the series.

Measurements for this Jig

Base 25in D x 32in L Pine Plywood

Front support 32 in 2x2 Length Select Pine

Back Support 8 in Length 2x2 Select Pine

Large Saw Base 4.5in X 25in

Small Saw Base 1 in x 25in (2)

Fence 1 in x 25in Miter attachment this well vary

Links to items I used

- Adhesive Measureing Tape http://amzn.to/2awzgAS

- Screw Cap Covers http://amzn.to/2aLSbIq

- T-nuts - http://amzn.to/2aLSbIq

- E-Z lock threaded insert http://amzn.to/2aLSbIq

Tools used

- Clamps http://amzn.to/1QdspQv

- Speed Square http://amzn.to/1QdspQv

- Framing Square http://amzn.to/1QdspQv

- Circular Saw http://amzn.to/1QdspQv

- Drill - http://amzn.to/1QdspQv

- Counter sink bit http://amzn.to/1QdspQv

- Hack saw http://amzn.to/1QdspQv

- Hand saw http://amzn.to/1QdspQv

Step 1: Cutting the Jig Base

Picture of Cutting the Jig Base

The base of your jig can be at any size for you feel is necessary for your space.

I made my jig 25 inches by 32 inches. 32 inches will be the width of the base.

Since this apart of my limited tool series I also made a guide to help viewers cut a straight line with a circular saw See video Link

Here is another Circular saw guide for more advance viewers.See Video Link

Step 2: Attaching the Front Support

Picture of Attaching the Front Support

The front support is measured at 32 inches in length. I use a 2 by 2 for this. If you want the max depth of your saw cut then consider using something larger that a 2 by 2. For example a 2 x 4 and ripping it to meet your needs.

I used a speed square as a guide to make the cut on the 2 by 2. Clamping the speed square is recommended this way you can focus on making a straight cut.

Now clamp the 32 inch support along the the edge of the base. Then flip the base upside done (stilled clamped).

Add screws along the edge. Pre drill and use a counter sink bit to flush mount the screws.

Step 3: Cut the Base for the Saw

Picture of Cut the Base for the Saw

This may varies on different brand of saws. For the large side of the base measure from the edge of the plate to the blade guide. Don't measure all the way to the blade. Keep in mind you want to see through the track where the blade will touch the blade.

Now using the saw guide make your first cut (for my saw I made this cut 4.75 in ). Then take the speed square to cut this piece of wood to 25 inches in length.

Make a second cut that will also be the support for the base this will be for the opposite side of the blade. (for my saw this was 1 in). This also needs to be cut to 25 inch in length.

To make the fence I need to cut one more piece of wood also measuring at 1 in. For the fence we will need (2) cut to 25 inch in length one for each side of the saw base.

Step 4: Attaching the Fence to the Base

Picture of Attaching the Fence to the Base

Now place the large base on a flat surface and clamp the fence to the base.

Add screws along the outside as shown in the picture. Then do the same for the small side of the base.

Step 5: Cutting the Back Support

Picture of Cutting the Back Support

Raise the saw to this max height then set the saw in the track.

Square up as shown in the picture. Then measure the back, middle, and the front of the track. Your should have the same measurement at all three points.

Take this measurement and cut the 2 by 2 for the back support.

Step 6: Attach the Track Guide

Picture of Attach the Track Guide

Set the back support on the rear of the base. Then place the large side of the track on the two support. I placed the track so that the saw blade sits approx 18 in from the end (referring to the side of where the stop block sit)

Take a 2 by 2 and clamp it down. Then take a framing square and square up the 2 by 2 to the front support. There should be no gaps in between the framing square and either 2 by 2.

Pull the large saw base to the 2 by 2 and clamp it down. One final time check the squaring on the track to the front support. If everything looks good clamp it down and screw it in place. Don't forget to flush the screws head so they clear the base plate of the saw.

Step 7: Attach the Back Support

Picture of Attach the Back Support

Attach the back support. As shown in the photos.

Step 8: Finishing Up the Saw Track

Picture of Finishing Up the Saw Track

Attach the other side to the saw track. Clamp it down first . The saw should move freely without friction but there should be no play within the track.

Screw the track in place.

Now drop the saw blade just enough to score the plywood base and then make your first cut.

Step 9: Adding the Miter Attachment

Picture of Adding the Miter Attachment

First thing first the edge of reference my be straight for this to work.

Now take the speed square and clamp it down like I have in the photo. A small square will work as well.

Insert the 2 by 2 and clamp it in place.The 2 by 2 should be butted up on the framing square.

Take the saw and cut the attachment.

To hold the attachment in place I used 1/4'' bolts and t nuts.

Drill the holes for the bolts using a 1/4'' bit so there will be not play in the hole.

Flip the jig over and install the t-nuts.

I end up cutting two of the bolts so they do not exit out the back of jig. Now install the Screws and and your jig is done.

Step 10: Quick Test

Picture of Quick Test

To check the accuracy cut a piece of wood and check your work with a framing square. It should be squared with out any gaps.

Step 11: Making the Stop Block

Picture of Making the Stop Block

The stop block is made from 1 by 2 pine.

I have many picture for this stop block. Its pretty self explanatory.

Thanks for checking out this instructables and good luck with your jig. Feel free to ask any question.

Comments

Maurice1967 (author)2017-05-01

Hi diycreators,

Thank you for this jig, very nice and easy to build.

Best regards

JonathanN88 (author)2017-04-29

anyone have cutting plan for this project? tia

rchmd19 (author)2016-08-18

I'm going to build this for my router.

jproffer (author)rchmd192016-08-18

why would you need it for a router?

NorbJ (author)jproffer2017-01-22

Dado for a bookshelf? Plenty of reasons. Some people are squeamish using routers, and having it in a track gives them the confidence to proceed. It's all good baby :)

Chatotazar (author)2017-01-19

Excellent tutotial, Thanks. The best jig i ever saw.

Regards

JShreve (author)2016-12-21

Gotta have it.

leorishaba (author)2016-11-04

I am making with some modification.

leorishaba (author)2016-11-04

It is very difficult to cut thin strip, need to modify this jig

genuel99 (author)2016-09-01

Very inspiring. I will definitely create one. Thanks and more power to you.

SherylinRM (author)2016-08-19

Once settled I plan to make this but with a couple of differences.

One, deeper to allow for cutting thicker wood.

Two, a separate platform UNDER the blade but on top of the one you made to cut thinner wood [make sense?]. Hmmm, essentially two table tops with one on top of the other. No clue if this is understandable lol.

Anyhow, I like it and voted for you :)

Very good video and instructable :)

JohnW51 (author)2016-08-18

Great project and great video. Wish I could work as fast as you do. ;-) I'm gonna check out your other projects. Thanks for posting,

bgunville (author)2016-08-18

Very nice jig. I will need to look at making once the move is completed and I have a new shop space. This will replace the extreme poor quality Ryobi miter saw.

hawgnutz (author)2016-08-18

Very nice job! This would be great for making picture frames, too!

jproffer (author)2016-08-18

nice 'ible! As an additional improvement, add nylon or teflon strips to either side of the inside of the guide, to prevent center drift with use over time. Alternatively, use a very hard hardwood or urethane coating.

cordovox (author)2016-08-18

A very helpful project and an excellent presentation.

Wolfbane221 (author)2016-08-08

really nice and accurate miter jig. Did you make this for your shop in place of a compound miter saw??

diycreators (author)Wolfbane2212016-08-08

Thank you. I have a miter saw. I am working on a limited tools series on youtube to help viewers with less tools and limited space.

zacatewo (author)diycreators2016-08-18

good idea, I think its the best aproach: work with fewer tools to work with more neurons :)

DinoD5 (author)2016-08-10

Thanks for the very creative project! I'm going to build one. I happen to have a piece of clear acrylic the right size for the base of the saw track - might use that just so i can see what's under there!

DonD10 (author)DinoD52016-08-18

I have some clear acrylic too, but I can't imagine how I'd keep it from scuffing after the first couple uses ... did you solve this? I like the idea of seeing through :-)

LexsperL (author)2016-08-18

great jig. Thanks for taking the time to share with everyone. Hope to make one soon with your plans. Well done and thanks again

Paul

michaeleensda (author)2016-08-12

Thank you. I tried to build something like this but it didn't turn so well. I'm going to start again and build this. The stop block is brilliant. It will solve a problem I had with making short cuts. I also really like the way you made this instructable. It makes it very easy to followI can't wait to see what you build next. - Steve

zencuke (author)2016-08-11

Very nice. Thank you. A simple to use safe and fast cross cut tool is one of the most important tools in a shop. 90% of the cuts most people make are 90 degree cut offs on long boards. This Instructable puts a good quality one within reach of beginners. I'm not a beginner and have both a miter/chop saw and two cross cut sleds for the table saw but I plan to make one of these for when I'm not in the shop. The chop saw can be moved but it is heavy. I'll probably follow @DinoD5 lead and use clear acrylic for the saw track. I always like to see what I am cutting mostly to make sure the wood is flush against the fence. It is so easy to get a bit of sawdust behind it and make a slightly un-square cut. I'm also looking to make a track saw so I might use the same tracking mechanism for both getting an accurate cross-cut and rip saw from the same circular saw.

OptimistSpencer (author)2016-08-10

Awesome project! I have a miter saw as well, but I have a jig like this that has a full 3' of crosscut space for cutting full size tabletops to length, but the thing is a huge time saver even on small cuts. I've always preferred radial arms to miter saws anyway, so using one of these makes me feel right at home. Again, great job- saw this featured and it definitely earned a vote/follow from me!

About This Instructable

46,247views

497favorites

License:

More by diycreators:DIY Desk Lamp DIY Makeup Vanity Desk How to Make a Fire Bowl
Add instructable to: