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CIRCULAR SAW
STATION
An Out of the Woodwork
Project Plan

Full build article & video:

outoftheww.com/projects/circular-saw-crosscut-jig
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Layout

3/4" Plywood 1x2 Red Oak

2x2 Red Oak

1x6 Red Oak

3/4 x 3/8 T-Track

© 2021  Out of the Woodwork

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Tools & Materials

Tools: Circular Saw

Drill
Tape Measure
Pencil
220 Grit Sandpaper
Eye Protection
Respirator
Clamps
Speed Square/Framing Square
3/4" Forstner Bit
1/4" & 5/16" Drill Bits

Materials: Wood Glue

1 1/2" Wood Screws
5/16" Fender Washers
T Track Hold Down Clamps/Toggle Clamps
T Track
T Bolt Kit 5/16" - 1 1/2" long
1/4" 20 Threaded Inserts
1/4" 20 Male 4 Star Knobs
5/16" hex bolts and nuts
CA glue or epoxy

© 2021  Out of the Woodwork

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Step 1

Making the Base and Front & Back Fences

Start with a 2' by 2' base made of 3/4" plywood.

Use wood glue and clamps to attach the fences to the base. Place them flush with
the edges of the plywood. It's not critical, but it helps to get them parallel to each
other. Measure from each end and make sure each measurement is the same.

If you are installing T Track, a 3/4" wide by 3/8" deep dado will need to be cut into
each of the 2x2 fence pieces before attaching them. I cut the dadoes with a router
and then squared off the ends with a chisel. It's not necessary to do this, but it
results in a better fit and finish.

© 2021  Out of the Woodwork

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Step 2

Making the Slide

Cut the 1x6 to the length between each outer edge of the front and back fence.

© 2021 Out of the Woodwork

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Step 3

Depending on your circular saw and its motor placement, you may need to rip a piece
of wood thinner than a 1x2. In that case, use the leftover 1x6 and rip the width you
need. Mine needed to be 1 1/8" and I show a method for doing this without a table
saw in the video for this project.

Attach the rail to the slide with wood glue and clamp it tightly.

© 2021  Out of the Woodwork

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Step 4

Use a framing square and/or speed square to align the slide "square" with the front
fence.

This is the most important part of building this station. The slide and front fence
should come together at an exact 90 degree angle. Clamp it temporarily and then
countersink a screw on the left side in the front and back.

90 Degrees

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Step 5

Drop your blade just below the bottom of the slide and run the circular saw along the
left rail cutting off the right side of the slide.

© 2021  Out of the Woodwork

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Step 6

Cut the right rail from 1x2 to the same length as the slide and glue it to the right side
of the slide.

© 2021  Out of the Woodwork

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Step 7

Building the Fence

No T Track, Fence Option

If you aren't using T Track, there is an alternate way to secure the fence. In the lower
piece of each fence guide, drill a 3/4" hole on the inside that will fit the head of a
5/16" hex bolt. This 3/4" hole should be the depth of the thickness of a 5/16" bolt and
nut - about 1/2", but don't drill all the way through with the 3/4" bit. Finish the hole
with a 5/16" drill bit.

Glue the nut in the bottom of the hole with CA glue or epoxy. Make sure the nut is
lined up with the smaller hole inside and no glue gets in the threads.

© 2021  Out of the Woodwork

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Step 8

After the glue dries, thread the bolt through until the head sits just under the
surface of the wood.

Run a nut down far enough to allow the threads to sit beyond the handle, so that an
additional nut can be added. Tighten both nuts and now the handle will turn the bolt.

© 2021  Out of the Woodwork

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Step 9

Glue the fence guide pieces together with wood glue and clamp them securely.

© 2021  Out of the Woodwork

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Step 10

If you are installing T Track, cut the dado in the top of the fence before installing the
fence guides.

Use a scrap piece of red oak pushed up against the slide to act as a reference. Push
the rip fence up against the reference piece and glue the fence guides to the fence
with wood glue and clamp them down.

After letting the glue set for about 30-45 minutes loosen the clamps and slide the
fence down to the edge of the plywood so you can add more clamps to it. Clamp
where the pieces meet the fence.

© 2021  Out of the Woodwork

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Step 11

Making the 45 Degree Guide

Using the same scrap piece to reference the slide, use a flat protractor to mark a 45
degree line.

It's important to reference from the slide itself and not the edge of the plywood.

© 2021  Out of the Woodwork

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Step 12

Clamp the 1x2 guide along the line and cut a test piece. Use the offcut placed up
against the 45 degree angle and measure the mitered corner to ensure it's 90 degrees.

With a 1/4" bit drill a hole down through the guide and just slightly into the plywood
base to make a mark. Remove the guide and finish the holes with a 5/16" bit.

Add some CA glue around the outside of the threaded inserts and screw them into the
holes.

© 2021  Out of the Woodwork

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Step 13

The guide can now be attached with 1/4" 20 male star knobs. You may need to recess
the holes with a wider bit if the threads on the knob don't reach the inserts.

© 2021  Out of the Woodwork

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Step 14

The T Track can now be cut to length and installed with the included screws.

© 2021  Out of the Woodwork

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Step 15

Mark a line on the fence guide in line with the t track and bring it around the
the front of the guide with a square. Drill a 5/16" hole and push the 1 1/2"
long T bolt through the back side.

Add a 5/16" fender washer and a 5/16" star knob.

© 2021  Out of the Woodwork

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When you're done post a picture of your finished creation on social media and tag
@oothewoodwork!

Check my website for more projects and plans just like this. I add new plans
periodically.

I hope you make time to get out in the shop and build this great shelf!

-Tommy (Out of the Woodwork)

outoftheWW.com

© 2021  Out of the Woodwork