When I started building jigs for my workshop a jigsaw was pretty much the only power tool I had at that time (except for my cordless drill). I needed to make cuts with different angles so decided to build a jigsaw cutting station.
There is honestly no saw more versatile than a jigsaw. It is a great multi-purpose tool that lets you make all sorts of different cuts – straight cuts, crosscuts, curves or even finishing the inside of corners. A jigsaw will let you make cuts a standard table saw can’t make still you will be able to do everything that a hand saw can. Apart from that, you can easily cut through different materials depending on the jigsaw blade – wood, plastic, and even materials such as ceramic or metal.
I’ve already built several jigsaw guides and crosscut jigs for my workshop but none could be used to make angle cuts.
The most useful and versatile jigsaw guide is the Jigsaw Guide and Crosscut Jig and the DIY Jigsaw Guide Rail. Achieving straight and accurate cuts is often not easy but a jigsaw guide rail definitely helps with that.
So.. Based on my previous experience with the DIY jigsaw guide rail I decided to build a jigsaw cutting station. It is basically a combination of the jigsaw guide rail and a table. It is easier to cut larger pieces of wood and you will be able to make clean 90 and 45-degree angle cuts.
Moreover, the jigsaw guide rail is not fixed to the jigsaw station and you can use it separately as necessary.
RELATED:
- 5 DIY Jigsaw Guides For Your Workshop from beginner to advanced woodworker
Latest & Relevant Videos
Watch the full video here – Jigsaw Cutting Station Video
Table of Contents
- Jigsaw Cutting Station Plans
- Jigsaw Related Questions
- How to Make a Jigsaw Cutting Station
- Build a Jigsaw Guide Track
- Jigsaw Cutting Station Table
- Jigsaw Cutting Station 90-Degree Cut
- Jigsaw Cutting Station 45-Degree Cut
- How to Use a Jigsaw Cutting Station
- Jigsaw Cutting Station Video
- 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. Safety comes first!
Always be cautious and careful when using any power tool.
What you'll need to build the Jigsaw Cutting Station
Jigsaw Guide Rail
Birch Plywood – (75 x 11 x 1,2 cm)
2x Planed Spruce Wood for stoppers- (8,4 x 2,8 x 1,2 cm)
2x Aluminum guide rails – (75 x 1,5 x 1,2 cm)
Jigsaw Cutting Station Table
Birch Plywood – (75 x 45 x 1,2 cm)
2x Planed Spruce wood (square) – (45 x 2,7 x 1,2 cm)
2x Planed Spruce wood (square) – (30 x 3,9 x 2,9 cm)
2x Planed Spruce wood (square) – (12 x 3,9 x 2,9 cm)
1x Planed Spruce wood (square) – (26 x 2,8 x 1,2 cm)
1x Aluminum L angle – (25 x 1,5 x 1,2 cm)
Other
16x bolts ø4, 1,6 cm + washers, nuts
2x Wing nuts ø6, washers
2x Threaded rod ø6 – 8cm
12x Wood Screws
ø4 Threaded insert, Wing Nut bolt 3cm, Washer
Epoxy
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Can you crosscut with a Jigsaw?
Yes, you can.
With a jigsaw, you will be able to make straight cuts, cross cuts, bevel cuts, and miter cuts. It will help you to cut circles as well as make plunge cuts. The variety of uses is really wide, which makes a jigsaw one of the best tools for woodworking beginners and DIYers.
There are many guides and jigs that can be used in combination with a jigsaw to achieve the best results for each of the individual types of cuts.
- For straight and precise cuts, it is desirable to use a jigsaw guide track. The resulting cuts will be cleaner and more accurate.
- For crosscuts and miter cuts, it is desirable to use a jigsaw cutting station. It allows crosscuts through materials of different widths and in combination with an adjustable fence you will be able to cut at any angle.
Can you make a 45 degree cut with a jigsaw?
Yes. A 45-degree cut is one of many types of miter cut that can be achieved with a jigsaw.
For shorter cuts with a jigsaw, a square can be used as a guide to achieving a 45-degree cut. To make a 45-degree cut through wider wood pieces or to cut at any angle it is better to use a jigsaw cutting station.
Let's Build It!
A jigsaw cutting station is a combination of a jigsaw guide track and a jigsaw table. The station is made of birch plywood, spruce wood, and aluminum rails.
The build is designed for a Bosch Jigsaw. Take into account the measurements of your jigsaw.
If you want to know why your jigsaw is not cutting a straight line and you are ending up with a skewed/beveled cut check out these jigsaw tips that will help you out.
How to Make a Jigsaw Cutting Station
Step 1: Build a Jigsaw Guide Track
First, let’s start with the Jigsaw Guide Track.
RELATED: You can also follow the process in this article – how to make a simple Jigsaw Guide Track.
Cut a rectangle for the jigsaw track. The base is 75 x 11 x 1,2 cm and is made of birch plywood.
If you cut the board slightly wider, the extra bit of wood can be cut off on a circular saw or a router table at the end if necessary.
NOTE: When cutting the base take into account 2 guide rails, a jigsaw shoe (if used), and a little bit of extra space between the jigsaw shoe and the aluminum rails that will allow for the jigsaw to slide easier.
I decided to use a 12mm thick plywood board. A thinner would work as well (9 mm) but I like how solid and sturdy the track is.
NOTE: I am using the jigsaw shoe with the guide rail. Using the cover will let the jigsaw slide easier on the track with less effort when pushing on the wooden surface.
The width of the shoe cover for my jigsaw is 8,4 cm – take into account the width of your jigsaw when building the guide rail.
Cut the aluminum guide rails to size.
Step 2: Attach Guide Rails to the Jigsaw Guide Track
1. Attach the first guide rail
Use a double-sided “carpet” tape to attach the guide rail to the base.
The tape is strong enough to hold the rail in place however additional fixing is necessary.
Fix the rail with ø4 bolts and nuts.
2. Attach the second guide rail
To secure the second guide rail, put the jigsaw on the base, place the second track along the other side of the jigsaw, and mark the position of the guide rail.
Take your time to position the track. Adjust the track as necessary and fix it temporarily with double-sided tape.
Secure the track with bolts and nuts.
Step 3. Attach Track Stoppers to the Jigsaw Guide Track
The stoppers are made of spruce wood.
Measure and cut them accordingly so they fit nicely between the guide tracks. They not only serve as stoppers for the jigsaw but also as a means of attachment to the table.
Fix the stoppers with glue and screws.
Step 4. Drill Sight Holes in the Jigsaw Guide Track
After attaching the jigsaw guide rails drill in holes across the jigsaw track using a 20 mm Forstner bit. They improve visibility and make it easier to follow a line while cutting.
Place the jigsaw on the track and cut a slot.
Sand both the edges and the surface of the jigsaw guide track to get rid of splinters and allow for the jigsaw to slide easier. This is what the finished Jigsaw Guide Track looks like.
Step 5. Build the Jigsaw Cutting Station Table
Now that we have the jigsaw guide rail let’s continue with the jigsaw table.
First, cut the table to size (75cm x 45cm x 1,2cm).
Glue 2 wooden stripes to both ends of the bottom of the table.
They serve as a good grip when cutting.
Step 6. Attach Wooden Legs to the Table
Cut 4 wooden bars and glue them to the bottom of the table.
NOTE: Gluing the bars will create a gap in which the jigsaw blade will run.
The height of the bars is greater than the length of the jigsaw blade I am using.
Though keep in mind NOT all jigsaw blades will fit. Use a blade of the right length.
Turn the table and additionally secure the bars with wood screws.
Step 7. Mount the Jigsaw Guide Track to the Jigsaw Table
Place the jigsaw guide rail on the table, adjust it and secure it with clamps. The guide rail should be 26 cm from the edge of the table.
NOTE: Check that the jigsaw guide track slot is centered above the gap.
Drill a hole to mark the position of the guide rail on the jigsaw table using a ⌀2 mm drill bit and then enlarge it with an ⌀8 mm drill bit.
Drill a ⌀20 mm hole in the jigsaw table with a Forstner bit and then a ⌀7,5 mm hole all the way through for a ⌀6 mm T-nut.
NOTE: As shown in the picture I placed the T-nut from above. I secured it additionally with epoxy and it works well – the fix is tight.
Nevertheless, you might consider placing the T-nut at the bottom of the table.
Drill a 20mm hole in the table on the cut line for the jigsaw blade.
Insert a ⌀6 mm threaded rod in the T-nut.
Place the jigsaw guide rail on the threaded inserts and fix it with wing nuts.
Once the jigsaw track is mounted to the table cut a slot.
TIP: Hold the jigsaw tight and cut the slot slowly so you don’t end up with a skewed cut. Also, make sure you are using the right jigsaw blade.
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Step 8. Attach a 90 Degree Crosscut Fence
Draw a few perpendicular lines to cut the slot.
These will serve for 90-degree and 45-degree angle cuts.
Glue a wood strip along the first drawn line. Additionally, fix it with screws.
This one will serve for 90-degree cuts.
Step 9. Attach an Adjustable Fence
Mark a 45-degree angle on the second line.
Draw parallel lines using an aluminum L angle that will serve as a guiding rail. (You can add additional angles in the same way)
Drill a 15mm hole in for a ⌀4mm T-nut.
Drill a 4mm hole in the center of the aluminum guide rail.
Cut out the side of the guide rail to make space for a butterfly wing bolt.
Attach the guide rail to the jigsaw table.
This is what the finished jigsaw cutting table looks like.
How to use a Jigsaw Cutting Station
Using a jigsaw cutting station is quite simple. It allows cutting larger pieces of wood/slats/boards more easily and allows to make straight cuts or angle cuts up to 90 degrees. Additionally, you can detach the jigsaw guide rail and use it separately.
- Clamp the jigsaw cutting station to a workbench
- Set the table fence to the desired angle
- Insert the workpiece between the jigsaw guide track and the table
- Secure the workpiece
- Mount the jigsaw in the track
- Slowly make the cut
NOTE: Keep in mind the length of the jigsaw blade.
Have trouble making a straight 90-degree cut with a jigsaw that is not skewed?
Check out these Jigsaw Tips!
My Take
I couldn’t be happier with how the jigsaw-cutting station turned out. The fact that I can use the jigsaw guide rail separately or in combination with the jigsaw table for a 90-degree or a 45-degree angle cut gives a huge benefit. A great enhancement for a jigsaw.
Unfortunately, the table takes up some space and it might be too large for a small workshop.
Ready to build a jigsaw crosscut sled? Let’s do it!
DIY Jigsaw Cutting Station Video
If you want to see how it is done, check out the video below for a step-by-step guide on how to make a jigsaw cut station.
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