I have built a few circular saw guides for my workshop, from very basic ones to more complex ones. Each of the guides has its advantages and their use varies according to the situation. These 4 DIY circular saw guides are the only guides you will need in your workshop.
This straight-edge guide for circular saws is quite detailed. It’s designed for both long straight rip cuts and crosscuts. You can use it to process larger sheets of plywood and to execute miter cuts at any angle.
If I had to choose which circular saw guide to make first again, I’d pick this one, especially for its capability to cut large wooden boards.
Features and Capabilities
- The track saw contains several pre-drilled clamping holes along the board for fixing the guide and cut material to the workbench as well as an anti-slip tape attached to the bottom of the guide when used without being attached to a desk.
- It is attached to a wooden shoe, which can be very easily mounted on the track. Such a design in comparison to a simple cutting straight edge guide holds the circular saw the entire time straight in position making sure the cuts are always straight and precise – basically, it works like a track saw. This is especially useful for the starting and ending cuts.
It took me around 3-4 hours to build the guide. All the material needed is readily available in any hardware store. I used Baltic birch plywood for the track and the wooden shoe, while the guide and runners were made using an aluminum angle bar and a flat bar.
This is not a project for complete woodworking beginners and some experience is needed. If you are just starting out, you might want to build this circular saw guide first.
Table of Contents
- The Material you will need
- General Questions
- 4 tips to make straight cuts with a circular saw
- How to make a Circular saw straight edge guide
- Step 1: Measure and cut the shoe for the Circular Saw
- Step 2: Cut 4 strips and attach them to the shoe
- Step 3: Make a plunge cut
- Step 4: Make a sliding bar
- Step 5: Cut the slot for the shoe
- Step 6: Attach the sliding bar to the shoe
- Step 7: Add a guide rail for better shoe stability
- Step 8: Add anti-slip tape
- How to use circular saw guide
- How to cut straight with a circular saw
- Tips for achieving the best result with a circular saw
- Circular Saw Straight Edge Guide Video
- Woodworking jigs used for the project
*Safety is your responsibility. Make sure you know what you’re doing and take all necessary safety precautions while working with power tools, especially with a circular saw. Safety comes first!
Always be cautious and careful when using any power tool.
Material needed to build a Circular Saw Straight Edge Guide
DIY Circular Saw Guide:
Plywood – 120 mm x 225 mm x 12 mm
Aluminum L Angle – 120 mm x 15 mm x 16 mm
Circular Saw Guide Shoe:
Plywood 9mm – 162 mm x 340 mm x 12 mm
Plywood 12mm – 162 mm x 20 mm x 12 mm
Aluminum flat bar – 380 mm x 20 mm x 4 mm
Aluminum L Angle – 200 mm x 14 mm x 12 mm
Other:
Drill bit – 2mm
Forstner bit – 35mm
M6 Bolts, M6 Wing Nut
Wood screws, File
Sandpaper, anti-slip adhesive tape
Double-sided “carpet” tape
Tools:
Circular Saw
Trimming Router
Hand Drill
Chisel
Benefits of Using a Track Saw Compared to a Circular Saw
When choosing between a circular saw and a track saw, understanding the unique advantages of each can greatly influence your decision. Here’s why a track saw might be a more beneficial choice over a circular saw for many users:
- Consistency: The rail system of a track saw ensures every cut is straight, giving you consistently accurate results.
- Safety: With its design, a track saw reduces the chance of kickbacks, making it safer and offering better control during operations.
- Flexibility: Track saws can handle a wide variety of materials with ease, especially larger sheets, giving the user more flexibility in projects.
RELATED: Circular Saw vs Track Saw
4 tips to make straight cuts with a circular saw
- Use a DIY circular saw cutting guide or a shop-made guide. A circular saw guide will help make accurate and precise cuts every time.
- Use a speed square. Using a speed square is one of the best and easiest ways to make short and precise cuts.
- Use a circular saw fence. Once attached to a circular saw the fence follows the edge of the material cut resulting in clean straight cuts.
- Use a track guide. The circular saw rides on a track which allows for making long straight rip cuts and crosscuts. The guide can be also easily adjusted and can make cuts at any angle.
Let’s begin!
I am using birch plywood for the build. Both for the saw track and the shoe. For the guides, I am using aluminum bars. A 4mm thick aluminum bar that is attached to the bottom of the shoe slides in the slot and one aluminum angle bar serves as an additional guide for the wooden shoe.
You could also use a wooden runner (bar) instead of the aluminum one, but the aluminum bar won’t change its shape as much due to external conditions.
The track saw can be used freely thanks to anti-slip strips, or it can be clamped down to a workbench with hold-down clamps. The cut circles on the track are designed specifically for this purpose.
This track saw guide is the jig you want to use if you want to cut large sheets of plywood.
Circular saw straight edge guide parameters:
- Total dimensions – 120 mm x 225 mm x 12 mm
- Straight cuts up to 1200 mm in length
- Quick assembly, quick setup
- Cutouts and drilled holes for easier manipulation and saw guide attachment
To build the saw guide you will need a circular saw, a trim router, and a hand drill. Some of the cuts can be made with a jigsaw instead of a circular saw. For smaller pieces and more delicate cuts, I am using a jigsaw table.
How to make a DIY circular saw straight edge guide
Step 1: Measure and cut the shoe for the Circular Saw
Measure the base plate of your circular saw. Mine is 300 x 132 mm. Add around 20 mm to the front, back, and sides, and cut a plywood piece that will serve as a shoe for the circular saw.
I am using a simple circular saw track to make the cuts.
Step 2: Cut 4 strips and attach them to the shoe
Cut 4 plywood strips and attach them to the plywood shoe tightly around the circular saw to fix the saw in position. I am using a jigsaw table for these delicate cuts.
Cut the front and the back strips to size. Attach the front strip to the base, wait until the glue dries, place the circular saw on the base for reference, and attach the back strip. Additionally, fix the strips with screws.
NOTE: The front and back edges of the circular saw’s base are usually raised. Ensure that the plywood strips you cut are taller than this base.
Repeat the process and attach the side strips around the circular saw. Since I had some leftovers in the workshop instead of wood strips, I am using aluminum L angles for the side attachments. There is no difference between those.
Step 3: Make a plunge cut
To finish the wooden shoe, make a plunge cut for the saw blade. Place the circular saw in the shoe, secure the shoe with clamps, and slowly make a plunge cut.
Get familiar with these circular saw safety tips before making a plunge cut and make sure you take all necessary safety precautions.
NOTE: Making a plunge cut with a circular saw requires skill and experience. If it feels unsafe to you or you don’t feel comfortable with it, don’t do it. Alternatively, you can also use a router or a jigsaw to achieve the desired cut.
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Step 4: Make a sliding bar
Take an aluminum bar measuring 380 x 20 x 4mm and drill multiple holes along its length. This bar will later be fixed to the shoe from underneath in step 6, functioning as a slider or miter bar. Remember to countersink the holes for a smooth finish.
Round the corners and edges of the bar to make it slide easier in a slot.
NOTE: While you could use a wooden bar, I wouldn’t advise it. The aluminum bar will glide smoothly in the wooden slot and remain unaffected by workshop temperature changes, ensuring consistent performance without expansion or contraction.
Step 5: Cut the slot in the track for the shoe
First, cut the plywood for the circular saw track to size (1200 x 230 x 12 mm). Since you don’t have a guide yet, you can use a straight edge like a lever to make long straight cuts.
Mark the position of the slot – 50 mm from the edge and cut a slot in the track guide either using a router dado jig or any straight edge that can serve as a guide for the router (a lever or an aluminum bar would do fine). Sand the edges of the slot.
NOTE: The width of the slot equals the width of the sliding bar. The cut depth should be just a bit more than the bar’s thickness.
It is better to make the slot tighter. You can always sand the edge and adjust. The right width of the slot should hold the miter bar tightly, allowing for a nice slide.
Step 6: Attach the sliding bar to the shoe
Apply epoxy on the aluminum bar, glue it to the bottom of the shoe, and secure it with screws (make sure the screws are countersunk).
The distance between the edge of the bar and the cut slot on the shoe should be just a little less than 50 mm.
Then place the circular saw with the shoe onto the guide track and cut off the wood excess. This way you will get a straight and clean edge.
Step 7: Add a guide rail for better shoe stability
First, drill a few holes with a Forstner bit along the cutting guide to be able to fix the guide and cut material with clamps to the workbench.
Place the shoe on the guide and mark the edge of the shoe in several places. Attach an additional aluminum rail along the marked places. The aluminum rail provides enhanced stability for the shoe and prevents it from tipping, ensuring straight and perpendicular cuts.
To attach the aluminum rail, I am using double-sided tape and screws.
Step 8: Add anti-slip tape
Add anti-slip tape to the bottom of the cutting guide. This way the guide will hold in position without being clamped down to a workbench.
This is a great weekend project and one of the “must have” saw guides for your circular saw. It is definitely one of the best circular saw jigs I am using the most for my projects.
How to use a DIY Circular Saw Guide for Straight Cuts
Provided steps below describe how to use a DIY circular saw guide and how to cut straight with a circular saw. Keep in mind to use the right saw blade for the job. Every material requires a different type of saw blade. Also, keep safe and take all necessary safety precautions.
How to cut straight with circular saw
- Mark the locations for the cut. Begin by carefully measuring and marking the desired cut line on your material.
- Align the circular saw guide with the marks. By ensuring that the guide edge matches your marked line, you’re setting up for a cut that stays true to your intentions.
- Firmly clamp down both the saw guide and the material. Securing them in place eliminates any chances of them shifting mid-cut
- Position the saw onto the guide track and make sure it sits snugly against the guide rail.
- Make sure nothing is obstructing the cut, both above and below the guide
- Make the cut
Tips for achieving the best result with a circular saw
- To achieve the best result, cut slowly and steadily. Keep the circular saw in a straight position, hold it with both hands, don’t push too fast, and let the circular saw do the work.
- In order not to damage your workbench or run your circular saw into concrete when working on the ground place an MDF desk or a rigid foam board under the cut material.
- Select the appropriate blades for the specific materials you’re cutting.
How to build a DIY straight edge for circular saw video
The video below shows step-by-step how to make a DIY straight edge for circular saw.
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I hope the information was helpful and now you are adding this circular saw jig to your next builds. 😉
