How to Cut an Octagon on a Table Saw
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Step 1: Make the Jig
To make the jig, cut one end of two 5" x 1" x 1" strips of hardwood at a 45-degree angle. Screw the strips of hardwood onto a 10" x 5" x 1" piece of plywood so they form a 90-degree angle (Image 1). Use a framing square to measure the angle, making sure it is exactly 90 degrees (Image 2).
Step 2: Cut a Perfect Square
Determine the desired length of the finished octagon (O). Cut the work piece in the shape of a perfect square, with the length of its sides (S) determined by the following formula: S = 2.414 x O. Cut the square S inches on each side.
Step 3: Set the Rip Fence
Calculate the rip distance (R) from the formula R = 2.914 x O. Set the rip fence at distance R. Place the jig against the rip fence so that the point where the two strips meet is against the fence.
Step 4: Use the Jig
To use the jig, align one corner of the square work piece with the 90-degree angle on the jig (Image 1). Hold the work piece on top of the jig as you send it through the table-saw blade (Image 2). Repeat step 4 to cut off the remaining three corners of the work piece.
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