How to Make a Circular Saw Crosscut Jig and Router Guide 2 in 1

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Introduction: How to Make a Circular Saw Crosscut Jig and Router Guide 2 in 1

About: Discover woodworking, concrete, LEDs, home decor and DIY projects you'll love.

This Circular Saw Crosscut Jig will open up a world of possibilities right in your own shop. You will be able to cut at various angles with ease, safely make dados, create half-lap joints, and work with an expanded cut capacity. Although this jig will not fully replace a miter or table saw, it serves many functions that those saws provide. Additionally, with a few easy adjustments, this build can also act as a router jig. This jig is sure to make your circular saw one of the favorite tools in your shop.

GET THE PLANS HERE: PLANS

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Material

  • (1) 36in 2in C-Channel LINK
  • (1)- 36in Blue T-track LINK
  • (1)- Hold Down clamp LIN K or Best Value get the - Kit LINK
  • (1) - Plywood base (Base)
  • (1)- 1 by 2 select pine (attachment)
  • (1)- 1 by 3 for the riser (can use plywood)

Tools

  • Dewalt Battery Powered Circular Saw - LINK
  • RIDGID- Octane Brushless Reciprocating - LIN K
  • Milwaukee M18 Cordless - LINK
  • Husky Mechanics Tool Set - LINK
  • Impact GOLD #2 Phillips - LINK

Gear

  • Dust Mask: LINK Use promo code DIYCreators to get 15% off.
  • Magnetic Wristband LINK

You can see my complete kit list here Link

Step 1: Routing the T-Track

First, make sure you are working with a straight piece of plywood. Then, mark the desired location of the T-Track. I attached a piece of scrap wood to the router guide to help stabilize and control the router. I worked my way up to 3/8th of an inch, by routing 1/8th inch at a time. I cleaned up the end of the track using a chisel and then sanded the whole base. Next, screw the T-Track in place using screws that will not exit through the back.

Step 2: Splitting the C-Channel

To create the saw track, I ripped a 2 inch C-Channel using a reciprocating saw with a metal blade. Although you would like to achieve a nice uniform cut, it does not have to be perfect; the goal is to have 2 tracks that the saw can ride on. Next, be sure to smooth the sharp edges of the C-Channel by filing and sanding.

Step 3: Recessing the Saw Guide

The tracks will be recessed in the risers. First, I lined the risers together and secured them so that they can be cut simultaneously. Then, I used a hand saw to make the outer cuts, and used a router to remove the section where the tracks would sit. A chisel can be used for this step.

Next, I lined up the riser on the base of the jig to mark where the T-Track screw will sit. I used a chisel to create a channel for the T-Track screw.

Step 4: Attaching the Risers

Again, you want to ensure the T-Track screw is in the T-Track before attaching the risers. Apply wood glue to the bottom of the riser and check for squaring before using clamps to secure. Then, use screws to attach the riser to the base. Repeat the same process on the opposite side with the other riser, assuring that it is square. Allow glue to dry.

Step 5: Adding Threaded Inserts

Place the tracks in the opening on the risers, and place the saw on top of the tracks to ensure the proper spacing. Drill a pilot hole through each end of the tracks and into the risers. You will want to countersink the screw holes so that the heads of the screws do not interfere with the saw. Install the threaded inserts into the holes in the risers. Screw the tracks into place.

Modify this jig for a router by moving one of the tracks to fit your router base. Drill a new hole into the risers, and add threaded inserts.

Step 6: Painting and Assembling

I used black paint to finish the metal tracks and the risers. Be careful not to get any paint inside of the tracks. After the finish of your choice dries, you can attach the tracks with screws.

Step 7: Blade Guard Holder

I used a bracket and formed it to act as a stop. I was able to use one of the existing holes and attach the bracket to the saw using a bolt.

Step 8: Miter Attachment

I cut 2 pieces of wood, one at 45° and the other at 22.5° and attached them to 2 separate pieces of wood as shown. I will utilize the bolt that is used for the hold down clamp as a pivot point. I clamped the two long pieces of lumber and used a drill press to drills in the same section. Keep in mind that these pieces could be any length that's comfortable for you, just make sure that they extend past the cut area of the saw blade. To ensure accuracy, use a speed square as a reference and use the knob to secure the lumber. Glue the angled piece of wood (as shown) making sure to leave no gaps between the speed square and lumber. Next, cut the excess wood from the bottom of the attachment.

To install these attachments, you will line them onto the T-Track screw, swing them on the track and tighten it down. I recommend that you double check the attachment with a speed square before every use. After ensuring the alignment you can cut down the attachments. When you use this attachment, you can use a clamp or a hold down clamp to hold your subject down.

Step 9: Test Cuts

As previously stated, this Circular Saw Crosscut Jig will prove to be a valuable addition to your shop. Hope you enjoy the versatility of this simple jig.

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    25 Discussions

    So I have to pay $3.99 plus whatever for the plans? Nice way to shill. I don't care how useful this might be. I'm not reading beyond that self promoting link.

    2 replies

    It's a joke, right? He is one of the few who makes such detailed videos at no cost.

    4 dollars is a fairly low cost compared to many others who sell their work.

    I do not need the plans, since I intend to adapt it to my needs, but I will buy them as a sample of support for their great work.

    Thanks Glenn, I am subscribed to all your channels and always waiting for a new video, you are a great craftsman.

    Who said you have to pay? I gave you all the details you need to tackle your own. Plans are optional, of course, I am going to promote myself. This helps me make more free content. I am providing free content which comes at a cost to me.

    0
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    AirTex

    21 days ago

    This is one of the nicest DIY jigs I've seen. Very well done.

    So simple but so damn useful, quite impressed! Well done!

    Will be making my own.

    Cheers Paul

    1 reply

    why not use 2 pieces of 1" angle iron and save the hassle of splitting the C channel?

    1 reply

    The C-Channel has a short lip, The lip of the c-channel was perfect. It didn't interfere with the base of the saw or motor. This allowed me to lower the saw all the way a get maximum cut. Angle Iron usually have two even sides. In my case, my saw and motor on the saw would hit the lip that's facing up. So instead of cutting two angle iron, I used a C-channel and one cut.

    ANY REASON NOT TO USE ANGLE IRON,INSTEAD OF HAVING TO CUT THROUGH THE C CHANNEL?

    1 more answer

    Yes, there is a reason I used the C-Channel. The C-Channel has a short lip, The lip of the c-channel was perfect. It didn't interfere with the base of the saw or motor. This allowed me to lower the saw all the way a get maximum cut. Angle Iron usually have two even sides. In my case, my saw and motor on the saw would hit the lip that's facing up. So instead of cutting two angle iron, I used a C-channel and one cut. Hope, I am making sense.

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    STAN D

    23 days ago

    ALL OF YOUR CREATIONS ARE JUST GREAT.ALWAYS ENJOY WATCHING A BUDDING GENIUS IN THE MAKING. KEEP UP YOUR GOOD WORK

    1 reply

    Very nice idea congratulations also help you you have a lod of tools for wood work God bless.

    1 reply

    Most of the things I had on hand but It should cost around $50.00

    Real sweet idea - Thanks a lot for sharing - mind you I really envy you - your shop setup looks great !!

    This is an awesome design. Thank you so much for sharing it :-) The idea of the two L-shaped guides for running a tool through is so obvious (I just hadn't thought of it.)