|
|
 |
|
|
| |
 |
|
|
| by:
Richard McCord
photos: Roger Yip
illustration: Len Churchill |
ACCURATE CUT SAWBOX |
| This
simple-to-build box ensures accurate circular saw cuts |
Sometimes it’s the little things—like making a square
cut in a reasonable amount of time without fancy equipment—that
trip up your project. Even with a handheld circular saw, it’s
no picnic. In fact, without experience, making accurate cuts
can be more difficult than with a handsaw, at least until you
build a sawbox. It guides the tilting base of any circular saw
for accuracy. If the box is square, your cuts will be, too—or
precisely angled, if that’s what you want. Control is what
this custom sawbox delivers.
 |
| The
author makes accurate cuts in some reclaimed siding
using his custom-built sawbox |
|
Any
sheet stock will do for this project. I used medium-density
fibreboard (MDF), but you could also use exterior-grade ply
or Baltic birch ply. Don’t buy anything special. You can
use solid wood for the saw support strips and guides, but you’ll
need the stability of sheet stock for the box base.
Before building, consider the
type of cuts you’ll make with the sawbox. If it’s
cutting 2 x 6 decking, for instance, consider a narrow base.
If you’re planning to build a picket fence, then a wide
base is sensible because you can trim multiple pickets at once.
The simplicity of this project allows you to quickly build different
sawboxes for different applications, so don’t try to make
a one-size-does-all model.
The front and back of the box
comes next. Select a width that matches the maximum cutting
depth of your saw, plus an allowance for the box base thickness.
If you’re building a box for beveled cuts, adjust the front
and back to match the reduced cutting depth of a tilted blade.
Secure the front and back pieces with #10 x 2" screws in
predrilled holes. Add weatherproof glue.
 |
| Space
the guide rails to the size of the baseplate on
your circular saw model |
|
Next
comes the support and guide rails. Join them into L-shaped assemblies
before installation and make them long enough to fully support
your saw before and after each cut. Use more glue and screws,
but this time choose shorter #10 x 1 1/4" ones so they
don’t go right through the parts. Here’s a customization
tip: some saw designs have a particularly wide area of swivelling
base underneath the motor. If that's the case, consider widening
the support rail on this side. You’ll get better support
and a steady saw action. Put the guide assemblies on your sawbox
and cut a plywood spacer 1/32" wider than your saw base
and as long as the guides.
Here’s where you need to
be careful in two ways. First, the guide assemblies must be
square to the front and back members (or true to the angle you
want the box to cut). Second, the guide assembly spacing must
be parallel and far enough apart so the saw can slide freely
but close enough to eliminate any side-to-side saw movement.
That’s why the plywood spacer guide is so helpful. Once
you cut one, keep it on hand for future sawbox construction.
The spacer will be useful for speeding construction and ensuring
accurate performance.
 |
| CLICK
ABOVE TO ENLARGE |
|
Fasten
one guide assembly to the front of the sawbox only with glue
and a single screw. Now, using a carpenter’s square, swivel
the guide rail until it’s exactly 90° to the front
of the box and secure it with a second screw into the top of
the box back. To position the second guide rail, put the plywood
spacer on top and the other guide assembly loose underneath.
Adjust the guide tight to the spacer. Glue and screw it down.
Now you’re ready to make your first cut, which will also
make the slots through the box’s front and back members.
Position the edge of the material to be cut tight against the
box front and hold it steady with your free hand. |
| You
Will Need |
| Part |
Size |
Qty. |
| Box
base |
3/4"
x 6"-18" x 25"-35" |
1 |
| Box
back/front |
3/4"
x 1 1/4"-2 1/2" x 25"-35" |
2 |
| Saw
support rails |
3/4"
x 5" x 25"-35" |
2 |
| Saw
guide rails |
3/4"
x 2" x 25"-35" |
2 |
|
|
|
|
|
| FREE
NEWSLETTER |
Subscribe to our newsletter. Every few weeks, you'll get a behind-the-scenes
peek at the magazine, the web site and the folks who put it all together.
CLICK HERE |
|
|
PROJECTS
