Easy Jigsaw Cutting Station For Your Workshop

A jigsaw cutting station you can easily build for your workshop. Learn how to build this jigsaw crosscut sled with step by step guide and video tutorial.

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). So I 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. 

I’ve already built several jigsaw guides and crosscut jigs for my workshop that turned out to be quite helpful when working on projects.

Probably the most useful and versatile one is the Jigsaw Guide and Crosscut Jig and the DIY Jigsaw Guide Rail. Having a guide rail for a jigsaw is really helpful. Achieving straight and accurate cuts is often not easy but a jigsaw guide rail definitely helps with that.

So.. Based on my 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.

I’ve been using the jigsaw cutting station/ jigsaw crosscut sled for multiple projects and I am happy about its versatility and the results I am getting.

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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Below I am providing step-by-step instructions on how to make a jigsaw cutting station/ jigsaw crosscut sled. Hope you enjoy it!

Table of Contents

*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)
16x bolts ø4, 1,6 cm + washers, nuts
2x Wing nuts ø6, washers
2x Threaded rod ø6 – 8cm

Jigsaw Cutting Station

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)
12x Wood Screws
1x Aluminum L angle – (25 x 1,5 x 1,2 cm)
ø4 Threaded insert, Wing Nut bolt 3cm, Washer

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Jigsaw Cutting Station | Jigsaw Cut Station | Jigsaw Crosscut Sled | AllFlavor Workshop

Can you crosscut with a Jigsaw?

Yes, you can.

A jigsaw is a multipurpose tool. Not only does it allow to cut through different materials depending on the blade used but also can be used to make all sorts of different types of cuts. With a jigsaw you will be able to make straight cuts, cross cuts, bevel cuts, 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 a straight and precise cut, it is desirable to use a jigsaw guide track or a jigsaw straight edge guide. The resulting cut will be cleaner and more accurate.

For a crosscut or a miter cut a jigsaw cutting station can be used. A cutting station allows to crosscut through materials of different widths and in combination with an angle ruler allows cutting at any angle.

Can you make a 45 degree cut with a jigsaw?

Yes. A 45-degree cut is one of many types of the miter cut.

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.

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.

Let's Build It

DIY Jigsaw Guide Rail

As mentioned above the jigsaw cutting station is a combination of a jigsaw guide rail and a table.

First, let’s start with the JIGSAW GUIDE RAIL.

RELATED: How to make a simple Jigsaw Guide Rail

Cut a rectangle for the jigsaw base. The base is 75 x 11 x 1,2 cm and is made out of birch plywood.

When cutting the base take into account 2 rails, a jigsaw shoe (if used), and a little bit of extra space between the shoe and the aluminum tracks that will allow for the jigsaw to slide easier.

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.

Jigsaw Cutting Station - dimensions
Jigsaw Cutting Station - cutting board

I decided to use a 1,2 cm 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 in 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 the width of your jigsaw into account when building the guide rail.

Jigsaw Cutting Station - Jigsaw width

Cut the aluminum guide rails.

Jigsaw Cutting Station - Jigsaw Guide Rail - rails
Jigsaw Cutting Station - Jigsaw Guide Rail - rails

Attach the Guiding Tracks

1) Attaching 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. 

Jigsaw Cutting Station - Jigsaw Guide Rail - rails
Jigsaw Cutting Station - Jigsaw Guide Rail - rails

Fix the rail with ø4 bolts and nuts.

Jigsaw Cutting Station - Jigsaw Guide Rail - rails
Jigsaw Cutting Station - Jigsaw Guide Rail - rails
Jigsaw Cutting Station - Jigsaw Guide Rail - rails

2) Attaching 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.

Jigsaw Cutting Station - Jigsaw Guide Rail - rails
Jigsaw Cutting Station - Jigsaw Guide Rail - rails

Then secure it with bolts and nuts. 

Jigsaw Cutting Station - Jigsaw Guide Rail - rails

3) Attaching the stoppers

I am using spruce wood for the stoppers. 

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.

Jigsaw Cutting Station - Jigsaw Guide Rail - stoppers

Fix the stoppers with glue and screws.

Jigsaw Cutting Station - Jigsaw Guide Rail - stoppers
Jigsaw Cutting Station - Jigsaw Guide Rail - stoppers

Drill in Sight Holes

After attaching the jigsaw guide rails drill in holes across the jigsaw track using a 25 mm Forstner bit. They improve visibility and make it easier to follow a line while cutting. 

Jigsaw Cutting Station - Jigsaw Guide Rail - sight holes
Jigsaw Cutting Station - Jigsaw Guide Rail - sight holes

Place the jigsaw on the track and cut a slot. 

Jigsaw Cutting Station - Jigsaw Guide Rail - cutting 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. 

Jigsaw Cutting Station - Jigsaw Guide Rail

Jigsaw Cutting Station Table

Now that we have built the jigsaw guide rail let’s continue with the JIGSAW TABLE.

First, cut the table to the desired size.

Jigsaw Cutting Station - dimensions

Glue 2 wooden stripes to both ends of the bottom of the table.
They serve as a good grip when cutting.

Jigsaw Crosscut Sled - hold bars

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.

Jigsaw Crosscut Sled - stands
Jigsaw Crosscut Sled - attaching stands

Turn the table and additionally secure the bars with wood screws.

Jigsaw Crosscut Sled - attaching stands

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. 

Check whether the jigsaw guide rail slot is centered above the gap. 

Jigsaw Crosscut Sled - attaching jigsaw guide rail

Drill a hole to mark the position of the guide rail on the jigsaw table using a small drill bit and then enlarge it with an ⌀8 mm drill bit.

Jigsaw Crosscut Sled - attaching jigsaw guide rail

Drill a ⌀20 mm hole in the jigsaw table with a Forstner bit and then a ⌀7,5 mm hole 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 from the other side.

Jigsaw Crosscut Sled - attaching jigsaw guide rail
Jigsaw Crosscut Sled - attaching jigsaw guide rail

Insert a ⌀6 mm threaded rod in the T-nut.

Drill a hole through the jigsaw table where the slot would be.

Place the jigsaw guide rail on the thresaded inserts and fix it with wing nuts.

Jigsaw Crosscut Sled - attaching jigsaw guide rail
Jigsaw Crosscut Sled - attaching jigsaw guide rail
Jigsaw Crosscut Sled - attaching jigsaw guide rail

Cut the slot.

TIP:

Hold the Jigsaw tight and cut the slot slowly so you don’t end up with a skewed cut. 
Use the right jigsaw blade.

Jigsaw Crosscut Sled - cutting a slot

Have trouble making a straight 90-degree cut with a jigsaw that is not skewed?

Check out these Jigsaw Tips!

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Jigsaw Cutting Station 90 Degree Cut

Draw few perpendicular lines to the slot.
These will serve for 90-degree and 45-degree angle cuts.

Jigsaw Cutting Station - jigsaw table 90 degree cut

Glue a wood stripe along the first drawn line. Clamp it and fix it with screws.

This one will serve for 90-degree cuts.

Jigsaw Cutting Station - jigsaw table 90 degree cut
Jigsaw Cutting Station - jigsaw table 90 degree cut

Jigsaw Cutting Station 45 Degree Cut

Mark a 45-degree angle on the second line.

Jigsaw Cutting Station - jigsaw table 45 degree cut

Draw parallel lines using an aluminum L angle that will serve as a guiding rail. (You can add additional angles in the same way)

Jigsaw Cutting Station - angle bar attachment

Drill a 15mm hole in for a ⌀4mm T-nut.

Jigsaw Cutting Station - T-nut attachment for angle bar
Jigsaw Cutting Station - angle bar T-nut attachment

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 the jigsaw table.

Jigsaw Cutting Station - aluminum angle bar
Jigsaw Cutting Station - aluminum angle bar
Jigsaw Cutting Station - aluminum angle bar
Jigsaw Cutting Station - jigsaw table 45 degree

Using a Jigsaw Cutting Station

Using this jigsaw crosscut sled is quite simple. It allows cutting larger pieces of wood/slats/boards more easily. You can make straight cuts or angle cuts up to 90 degrees.

Additionally, you can detach the jigsaw guide rail and use it separately.

Also, you can easily clamp the jigsaw cut station to a workbench using ordinary clamps.

However, keep in mind the length of the jigsaw blade. 

Jigsaw Cutting Station | Jigsaw Crosscut Sled - using a jigsaw guide rail
Jigsaw Cutting Station | Jigsaw Crosscut Sled - 90 degree cut
Jigsaw Cutting Station | Jigsaw Crosscut Sled - 90 degree cut
Jigsaw Cutting Station | Jigsaw Crosscut Sled - 45 degree cut
Jigsaw Cutting Station | Jigsaw Crosscut Sled - 45 degree cut

I couldn’t be happier 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. 

So…

Ready to build a jigsaw crosscut sled? Let’s do it! 

HAPPY BUILDING!

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Jigsaw Cutting Station | Jigsaw Cut Station | Jigsaw Crosscut Sled | AllFlavor Workshop

I hope the information shared in this post sparked an idea and inspired you to build a jigsaw cutting station. Share your thoughts in the comment section below.

How to make a DIY Jigsaw Cutting Station

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