How to Make a Straight Line Jig for a Table Saw

Building the Jig

• 1

  Measure a 48-inch length on a ¾-inch plywood board. Mark the length with a pencil. Cut the board to length with a saw.

• 2

  Repeat Step 1 with another ¾-inch plywood board.

• 3

  Measure a width of 12 inches on one of the ¾-inch plywood boards using a tape measure. Mark the width with a pencil and cut the board to width with a saw.

• 4

  Measure a width of 4 inches on the other ¾-inch plywood board using a tape measure. Mark the width with a pencil and cut the board to width with a saw.

• 5

  Find the midpoint of the 4-inch-wide board lengthwise with a tape measure. Mark the midpoint with a pencil.

• 6

  Place the 4-inch-wide board on top of the 12-inch wide board so ends of the boards line up. Align the 4-inch-wide board in the middle of the 12-inch board, so it sits about 4 inches from each side.

• 7

  Check to ensure you have 90-degree angles at the corners of the 4-inch wide board using a square.

• 8

  Drill a 1 ¼-inch screw through the midpoint of the boards to affix them to one another.

• 9

  Measure a distance of 3 to 4 inches in from each end of the 4-inch-wide board, using a tape measure. Place the outer edge of a toggle clamp at each point, so you have one clamp at each end of the board.

• 10

  Attach the two toggle clamps placed on the board in the previous step to the board, using a drill and screws provided by the clamp manufacturer.

• 11

  Measure the distance from the inside edge of each toggle clamp to the screw in the center of the 4-inch-wide board, using a tape measure. The distances should be equal.

• 12

  Measure a distance equal to two-thirds of the distance between the inside edge of the toggle clamps and the center screw, starting from the inside edge of the toggle clamps and measuring toward the center of the board. Mark the distance with a pencil.

• 13

  Place the outside edge of a toggle clamp at each pencil mark drawn in the previous step. Attach the toggle clamps to the 4-inch-wide board as you did with the previous clamps.

• 14

  Drill one 1 ¼-inch screw through both boards from the top down, placing the screws equidistant from the end and center clamps on each end of the boards

Using the Jig

• 15

  Measure the piece of wood you want to make a straight cut or rip in. Place the wood on the table and line the cut mark up with the table saw blade.

• 16

  Place the jig on the table so the toggle clamps face toward the blade and the edge of the 12-inch board that the toggle clamps face abut the wood you want to cut.

• 17

  Adjust the fence on the table saw so it sits tight against the outside edge of the 12-inch board at the bottom of the jig.

• 18

  Adjust the toggle clamps so they sit on top of the board you intend on cutting and hold it in place.

• 19

  Turn on the table saw and move the board you intend on cutting forward, using the toggle clamps to hold it down and the 12-inch-wide board as a guide for a straight cut.