Cutting small parts on a table saw can be a dangerous task unless you know the proper techniques. One such technique involves using a jig that eliminates 99 percent of the danger by enabling users to keep their hands far from the blade. Here's how to make such a jig. Materials:
Table saw
Base: one sheet of 3/4" plywood, same length as guides and 2' wide
Guides: two strips of 1"-thick wood, length equal to the width of the table saw, width the same as the table saw's miter-gauge slots
Drill
Dry-wall screws
Two 3" x 1 1/2" x 1" wood blocks
Two clamps
Drill press
Four T-nuts
Four 3/8" bolts
- Use the table saw to cut a slot through the center of the plywood base.
- Place the guides in the slots on either side of the table saw's blade. Center the plywood base on top of the guides (figure A).
- Use dry-wall screws to secure the base to the two guides (figure B).
- Use a drill press to drill two holes in each 3" x 1 1/2" x 1" block to accept the T-nuts (figure C). Insert the T-nuts into the holes.
- On the opposite sides of the 3" x 1 1/2" x 1" blocks, drill a 3/8" hole above each T-nut to accept the bolts (figure D).
- Place the blocks on either side of the plywood base, and hold them down with the clamps. Screw the bolts through the 3/8" holes (figure E).
- To use the jig, place the work piece above the slot on the jig, with the line you want to cut aligned with the slot (figure F). Place a scrap piece of wood on top of the work piece, and clamp it down (figure G). Raise the table-saw blade through the slot in front of the work piece. Slide the jig across the blade to cut through the work piece.
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