How to Make a Table Saw Fence And Rail

For a table saw to cut accurately, the saw's fence must be able to remain perfectly parallel to the blade at any position on the table. When locked in the desired position, the locking mechanism should not allow the fence to slide, nor should there be any deflection from front to back. Any of these deficiencies could create dangerous kickback when cutting with the saw. You can make a table saw fence and rail that has these desired qualities and can adapt to nearly any type of table saw.

Tape measure
Table saw
Hacksaw
T-style table saw fence assembly with locking handle
2-inch by 3-inch square tubing
1-inch wide angle iron
Power drill with bits
8 Mounting bolts, each with 2 washers, 1 lock washer and 1 nut
Socket set
Allen wrenches
Pencil

Instructions

- 1
  Measure the distance from the left side of the table saw's table to the right side of the table with a tape measure.
- 2
  Cut a section of 1-inch angle iron and a piece of 2-inch by 3-inch rectangular tubing to the length you determined earlier with a hack saw.
- 3
  Hold the section of tubing against the front edge of the table saw, with the 3-inch side facing up. The top edge of the tubing should be about 1/2 inch below the top of the saw table. Mark hole locations from the edge of the saw onto the square tubing with a pencil.
- 4
  Drill bolt holes at the marked locations on the square tubing using a power drill. Then fasten the tubing to the front edge of the table saw using the bolts, washers, lock washers and nuts. Hand-tighten the nuts only at this point.
- 5
  Hold the angle iron against the back rail of the saw table, with the protruding portion of the angle iron flush with the table top. Mark hole locations onto the angle iron, then drill the holes and mount the angle iron using the bolts, washers, lock washers and nuts. Once again, only hand-tighten the nuts at this stage.
- 6
  Set the fence assembly on the table top, with the locking mechanism on the front edge of the saw. Adjust the height of the front tubing and rear rail so that the fence is positioned just slightly above the saw table at any position along the rail. After making the requisite adjustments, tighten the bolts and nuts to lock the tubing and angle iron in place.
- 7
  Slide the fence to a position where one edge of the fence is aligned with the edge of one of the saw's miter slots. Tighten the fence locking mechanism, and feel along the intersection of the fence and the miter slot with your finger. The fence and miter slot should be perfectly aligned. If the fence is angled slightly to the right, loosen the locking mechanism and tighten the adjustment screw on the right side of the locking mechanism with an Allen wrench. If the fence is angled slightly to the left, adjust the left adjustment screw. Keep making adjustments until the fence and miter slot are perfectly aligned.
- 8
  Raise the table saw blade and make a test cut. The saw should cut smoothly with no binding, nor should the edge of the board ease away from the fence while making the cut.

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