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 a lot of crosscuts and cuts at 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 Jigsaw guide rail I decided to build a Jigsaw cutting station. It is basically a combination of the jigsaw guide rail and a table. The combination makes it much easier to cut larger pieces of wood, make straight cuts and crosscuts, and clean 45-degree angle cuts.
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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Table of Contents
- Jigsaw Cutting Station Video
- Jigsaw Cutting Station Plans
- Materials and Tools Needed
- 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
- 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 – (750 x 110 x 12 mm)
2x Planed Spruce Wood for stoppers- (84 x 28 x 12 mm)
2x Aluminum guide rails – (750 x 15 x 12 mm)
Jigsaw Cutting Station Table
Birch Plywood – (750 x 450 x 12 mm)
2x Planed Spruce wood strips – (450 x 27 x 12 mm)
2x Planed Spruce wood strips – (300 x 39 x 29 mm)
2x Planed Spruce wood strips – (120 x 39 x 29 mm)
1x Planed Spruce wood strips – (260 x 28 x 12 mm)
1x Aluminum L angle – (250 x 15 x 12 mm)
Check all the Tools I Use
Tools:
Circular Saw – https://amzn.to/4aMD0xg
Jigsaw – https://amzn.to/3S85cDr
Hand Drill – https://amzn.to/3HqLEnH
One Hand Clamps – https://amzn.to/48jGxkZ
Spring Clamps – https://amzn.to/41Nuh9D
F-Clamps – https://amzn.to/48ArzY1
Large L Angle – https://amzn.to/4aGaT2D
Tape Measure – https://amzn.to/3TN0SKM
Center Hole Punch – https://amzn.to/48Fq7mv
Hand Saw – https://amzn.to/48if4Qz
Machinist Square / Speed Square
Other
Double-Sided Woodworking Tape – https://amzn.to/3tPMGpM
Wood Glue – https://amzn.to/48ltKhJ
Epoxy – https://amzn.to/3tJ5R4L
Sandpaper Sheets – https://amzn.to/41OMx2p
Forstner Bits – https://amzn.to/3Hd1aDb
Jigsaw Blades – https://amzn.to/4aXeF83
Jigsaw Blades (Extra Clean Cuts) – https://amzn.to/3TcPuWV
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 30 mm, Washer
Hardware Assortment Kit – https://amzn.to/41PodgQ
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Can you crosscut with a Jigsaw?
A jigsaw is versatile, enabling you to create straight, cross, bevel, and miter cuts. It’s even handy for crafting circles and executing plunge cuts. The range of possibilities makes it an excellent tool for both woodworking beginners and DIY enthusiasts.
There are plenty of guides and jigs out there that you can pair with a jigsaw for top-notch cuts of all kinds.
- For really straight cuts, adding a jigsaw guide track can make a big difference, giving you cleaner and more spot-on results.
- When it comes to crosscuts and miter cuts, having a jigsaw cutting station helps a lot. It can handle various material sizes and, with an adjustable fence, lets you cut at different angles easily.
Can you make a 45 degree cut with a jigsaw?
Yes, a 45-degree cut is just one of the miter cuts you can make with a jigsaw.
For shorter cuts, using a square as a guide can help you nail that 45-degree angle. But if you’re working with wider pieces or need cuts at various angles, a jigsaw table-cutting station is the way to go.
Keep in mind, the blade you choose greatly affects the accuracy and cleanliness of your cuts. Always select the appropriate blade for the task. For neater straight cuts, go for a wider blade that has more teeth.
10 TPI reverse-pitch tooth pattern for extra clean top surfaces when cutting in hard and soft wood, plywood.
Let's Build It!
A jigsaw cutting station blends a jigsaw guide track with a jigsaw table. It is crafted from birch plywood, spruce wood, and aluminum rails. The guide rail isn’t permanently attached to the station, so you can use it on its own whenever you need to.
This setup is tailored for a Bosch Jigsaw, but remember to adjust for the size 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 detachable Jigsaw Guide Track for straight cuts.
Cut a rectangle for the jigsaw track. The base is 750 x 110 x 12 mm 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’m pairing the jigsaw shoe with the guide rail, and using a cover helps the jigsaw glide more smoothly along the track, requiring less effort to push through the wood.
My jigsaw’s shoe width is 84 mm—make sure to consider the width of your jigsaw when constructing 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 double-sided tape (carpet) to attach the guide rail to the base. The tape is strong enough to hold the rail in place temporarily however additional fixing is necessary.
Fix the rail with M4 bolts and nuts.
2. Attach the second guide rail
To attach the second guide rail, set the jigsaw on the base and align the second track on the opposite side of the jigsaw. Then, mark where the guide rail goes.
Carefully position the track, making adjustments as needed. Temporarily secure it in place 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. Use the right jigsaw blades for plywood.
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 table.
First, cut the table to size (750 x 450 x 12mm).
Glue 2 wooden strips to both ends of the bottom of the table. They add extra thickness to the table and serve as a grip when cutting.
Step 6. Attach Wooden Legs to the Table
Cut 4 wooden bars and glue them to the bottom of the table. Leave a gap for the jigsaw blade between the bars.
NOTE: The bars are thicker than the jigsaw blade I’m using, so my blade fits well. However, remember that not all jigsaw blades will fit. Make sure to choose a blade of the appropriate 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 260 mm 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: You can place the T-nut from above and secure it additionally with epoxy. Or once you screw the threaded rod through, you can add a nut from 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. Use a large square to make sure the fence is attached at 90 degrees.
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 and attach it 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 straightforward. It simplifies the process of cutting larger pieces of wood, slats, or boards, enabling you to make straight or angled cuts up to 90 degrees. Plus, the jigsaw guide rail can be detached and used on its own.
- 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: Remember to consider the length of the jigsaw blade to avoid hitting the table underneath.
Do you have trouble making a straight 90-degree cut with a jigsaw that is not skewed?
Check out these Tips: How to Cut Straight With a Jigsaw
My Take
I’m really pleased with the outcome of the jigsaw cutting station. Being able to use the jigsaw guide rail on its own or together with the jigsaw table for precise 90-degree or 45-degree cuts is a major plus. It significantly boosts the versatility of a jigsaw.
The only downside is that the table requires a bit of room, which might not suit smaller workshops. However, if you’re looking for a single jigsaw jig that can handle a wide variety of cuts, this is the one.
Ready to build a jigsaw table cutting station? Let’s do it!
I hope the information shared in this post sparked an idea and inspired you to build a jigsaw table cutting station. Share your thoughts in the comment section below.
