I have built several jigsaw guides for my workshop, from simpler to more complex. This is the most complex jigsaw guide I’ve built so far combining several different guides into one (mainly the jigsaw guide track and the jigsaw crosscut jig). The primary advantage of this new guide is its ability to assist in achieving accurate straight cuts, suitable for both rip and crosscuts.
One of the main benefits is the adjustable crosscut fence. It allows for easy fine-tuning, ensuring cuts are perfectly straight and perpendicular.
The guide track contains several pre-drilled “sight” holes for better visibility when making straight cuts as well as several cutouts and holes in the base for better stock grip when crosscutting.
The larger size of the guide allows for accommodating longer pieces of wood. It can be used freely or clamped down to a workbench for better stability and accuracy.
All the material needed for this guide is readily available in any hardware store. The base is made of plywood and aluminum angles are used for the tracks and the crosscut fence. See below for a complete list of required material.
If you have some experience with woodworking and building DIY woodworking jigs, then you will have no problems making this jigsaw guide. Nevertheless, if you are a complete woodworking beginner, I suggest you start with one of the simpler guides mentioned above.
They work just as well, and you can achieve great results with them too. I’ve relied on them for numerous projects and they’ve never let me down.
DIY Adjustable Jigsaw Guide Video
If you want to see how to make a Jigsaw straight cut guide and crosscut guide, watch the video below for step-by-step isntructions.
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Table of Contents
- Adjustable Jigsaw Guide Video
- Jigsaw Straight Guide Plans
- The Material you will need
- How to Make an Adjustable Jigsaw Guide
- Step 1: Cut the jigsaw guide base
- Step 2: Cut the slot for the crosscut fence
- Step 3: Attach the aluminum guide rails
- Step 4: Drill the sight holes and clamping holes
- Step 5: Cut the slot in the track
- Step 6: Attach the crosscut fence
- Step 7: Attach the handle
- How to Make Straight Cuts and Crosscuts with a Jigsaw Guide
- Straight cuts with a jigsaw guide
- Crosscuts with a jigsaw guide
- Woodworking Jigs Used
*Safety is your responsibility. Make sure you know what you’re doing and take all necessary safety precautions while working with power tools. Safety comes first!
Material needed to build an
Adjustable Jigsaw Cutting Guide
Jigsaw Straight Edge Guide:
Plywood – 370 mm x 550 mm x 12 mm (14,5 x 21,6 x 0,47″)
Aluminum Rails – 550 mm x 15 mm x 12 mm (thickness 1,5mm)
Check all the Tools I Use
Tools:
Jigsaw – https://amzn.to/3S85cDr
Hand Drill – https://amzn.to/3HqLEnH
Trim Router (optional) – https://amzn.to/3HbQcOg
Spring Clamps – https://amzn.to/41Nuh9D
F-Clamps – https://amzn.to/48ArzY1
Chisel Set – https://amzn.to/3tHNJrT
Center Hole Punch – https://amzn.to/48Fq7mv
Other:
Drill bits – 6mm – https://amzn.to/4aI47t3
Forstner bits – 20mm, 35mm – https://amzn.to/3Hd1aDb
Double-Sided Woodworking Tape – https://amzn.to/3tPMGpM
Epoxy – https://amzn.to/3tJ5R4L
Handle
M6 Bolts, M6 Wing Nut
Wood screws (shorter for aluminum rails, longer for handle) – https://amzn.to/41PodgQ
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Let's Start
The base of the jigsaw guide is made of 12mm plywood. The L-angle bars are from aluminum and are used for the guide tracks and the crosscut fence. All the material is readily available in local stores.
Benefits:
- The guide can be used freely or it can be clamped down to a workbench with hold-down clamps. The protrusions on the baseboard are designed specifically for this purpose.
- The jigsaw guide is equipped with a handle for easier manipulation and there are several cutouts and holes drilled in the base for better visibility and stock grip.
- When crosscutting the crosscut fence can be adjusted and fixed as needed to make sure the cuts are made exactly at 90 degrees.
Parameters:
- Total dimensions – 370 x 550 mm
- Straight cuts up to 400 mm in length
- Aluminum track guides with predrilled sight holes for better visibility
- Cutouts and drilled holes for easier manipulation and stock grip
- Adjustable crosscut fence for a precise 90-degree cut
To build the jigsaw guide you will need a jigsaw and a hand drill. Additionally, you could use a router together with a router circle cutting jig (for routing a slot in the base) but it is not necessary and you can use the jigsaw to cut the slot.
I am also using a chisel to cut a hexagon in the baseboard to align an M6 bolt’s head with the base surface, but this is also optional. A non-countersunk bolt will work just as well.
How to Make an Adjustable Jigsaw Guide for Straight Cuts and Crosscuts
Step 1: Cut the jigsaw guide base
For the base, you will need a plywood board (370 mm x 550 mm x 12 mm).
Draw the design on the plywood board and cut out all the unnecessary pieces. To cut the shape you can use a jigsaw. I am using a simple jigsaw guide for straight cuts I built earlier. For the internal cuts use a Forstner bit first and then cut with a jigsaw.
NOTE: When building the track, take into account the width of your jigsaw shoe. The base part for the track needs to accommodate the jigsaw base, the aluminum tracks, and some extra space on each side for clamping.
Step 2: Cut the slot for the crosscut fence
Draw a line on the jigsaw base where you want to place the crosscut fence. Mine is 105 mm from the bottom of the jigsaw base.
Drill a 4mm hole for a pivot point on one side and cut a 6mm slot for a rider on the other side (right before the track) that will secure the crosscut fence in position. To cut the slot I am using a router circle cutting jig. (To make the t-slot I cut a slot through the board base first and then trimmed the wood around to fit a t-track bolt and make it flush with the surface).
NOTE: Making a t-track slot for a t-track bolt might be unnecessary. This is quite a complicated and time-consuming approach. I wanted the t-track bolt to be flush with the surface giving the jigsaw guide a fancy look, but fixing the crosscut fence in position can be achieved in simpler ways.
You can just as well cut one slot through the base and fix the bolt in position with a nut – in this case, the adjustable bolt will not slide in a t-track and will be secured directly through the main slot.
Step 3: Attach the aluminum guide rails
Frist Guide Rail – Attach the first guide rail to the jigsaw base. Cut it to length, drill in holes for the screws, attach a double-sided tape on the bottom of the rail, and tape it to the base.
Secure the rail to the base with screws and washers. If the screws go through, grind the tips with a sander. The bottom of the jigsaw base must be smooth without protrusions.
Second Guide Rail – Attach the second guide rail to the base. Place the jigsaw on the base next to the first rail, tape the second rail on the base, and repeat the previous steps.
Make sure the jigsaw slides nicely and easily in the created track. Now is the time to adjust the rails as needed. Once finished, fix the second rail with screws.
NOTE: I am using a jigsaw shoe with my jigsaw. The jigsaw slides better on the surface and there is less resistance from the tracks.
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Step 4: Drill the sight holes and clamping holes
Mark the center of the track – the cut path – and drill in sight holes using a 20mm Forstner bit every 50 mm.
Also, cut 3 holes with a 35mm Forstner bit right below the crosscut fence. These holes are useful for clamping down the jigsaw guide to the workbench and securing the stock when crosscutting.
Step 5: Cut the slot in the track
Cut a slot in the track for the jigsaw blade. Start in the first sight hole, and finish in the last one. Optionally, you can sand the cut path with sandpaper to get rid of splinters.
Step 6: Attach the crosscut fence
Pivoting point – Drill a hole for an M6 bolt in the previously drilled pivot point. Carve a hexagon with a chisel around the drilled hole to sink in the bolt’s head. Thus, the bolt won’t move. (Instead of carving a hexagon you can always drill a larger hole for the bolt’s head and fix it in with epoxy)
T-track – To adjust the fence and secure it in position I am using a simple t-track and a t-track bolt. The t-track bolt is a rider that fits in the cut slot. Carve a hexagon in the rider and insert an M6 bolt.
Crosscut fence – the crosscut fence is 260 mm long and is made of an aluminum L-angle bar.
Drill 2 holes in the bar – 1 for the pivot point, and 1 for the t-track bolt. Mount the crosscut fence on the bottom of the jigsaw guide base and fix it with nuts.
Step 7: Attach the handle
Finally, I am attaching a handle to the base. Adding a handle is a smart choice. It makes using the jigsaw guide both simpler and safer.
Conclusion
If you want to have an all-in-one solution then this jigsaw guide has it all – you can make both long straight cuts and crosscuts with possible fine adjustment, ensuring your cuts are always spot-on at 90 degrees. It’s a great addition to your jigsaw and a fun weekend project to tackle.
How to make straight cuts and crosscuts with a jigsaw guide
The following steps briefly describe how to make straight cuts and crosscuts with this DIY adjustable jigsaw guide. Keep in mind to use the right jigsaw blade for the job. Using the right blade is one of the most important things when cutting with a jigsaw to end up with a clean and straight cut.
Straight cuts with a jigsaw straight edge guide
- Place the jigsaw guide over the stock and align it using the sight holes
- Secure the jigsaw guide and the stock with clamps
- Make sure nothing is obstructing the cut path, both above and below the guide
- Place the jigsaw on the track
- Slowly make the cut, keeping the jigsaw straight
- Track the progress using sight holes
Crosscuts with a jigsaw crosscut guide
- Place the stock below the jigsaw guide
- Align it with the crosscut fence
- Make adjustments to the crosscut fence as necessary
- Place the jigsaw on the track
- Hold the stock with your hand or secure it with hold-down clamps using the grip holes
- Make sure nothing is obstructing the cut path, both above and below the guide
- Slowly and steadily make the cut
- Track the progress using sight holes
Read the following article for more information on how to cut straight with a jigsaw and how to avoid common mistakes that make your cuts skewed and bent.
To achieve the best result, cut slowly and steadily. Keep the jigsaw in a straight position, don’t push it, and let the jigsaw do the work.
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