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). 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. 

I’ve already built several jigsaw guides and crosscut jigs for my workshop but none could be used to make angle cuts.

Jigsaw Cutting Station | Jigsaw Crosscut Sled - 90 degree cut

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: Check out these 5 DIY Jigsaw Guides For Your Workshop from beginner to advanced woodworker.

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Watch the full video here – Jigsaw Cutting Station Video

Table of Contents

  1. Jigsaw Cutting Station Plans
  2. Jigsaw Related Questions
  3. How to Make a Jigsaw Cutting Station
    1. Build a Jigsaw Guide Track
    2. Jigsaw Cutting Station Table
    3. Jigsaw Cutting Station 90-Degree Cut
    4. Jigsaw Cutting Station 45-Degree Cut
  4. How to Use a Jigsaw Cutting Station
  5. Jigsaw Cutting Station Video
  6. 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.

Jigsaw Cutting Station Plans

Download the Free Jigsaw Cutting Station Plans here.

Free Downloadable Jigsaw Cutting Station Plans

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

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.

  1. For straight and precise cuts, it is desirable to use a jigsaw guide track. The resulting cuts will be cleaner and more accurate.
  2. 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.

Jigsaw Cutting Station - dimensions
Jigsaw Cutting Station - cutting board

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.

Jigsaw Cutting Station - Jigsaw width

Cut the aluminum guide rails to size.

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

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. 

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. 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.

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

Secure the track with bolts and nuts. 

Jigsaw Cutting Station - Jigsaw Guide Rail - rails

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.

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

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. 

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.  This is what the finished Jigsaw Guide Track looks like.

Jigsaw Cutting Station - Jigsaw Guide Rail
Finished Jigsaw Guide Rail

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).

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

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.

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

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.

Jigsaw Crosscut Sled - attaching jigsaw guide rail

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.

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 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.

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

Drill a 20mm hole in the table on the cut line for the jigsaw blade.

Jigsaw Crosscut Sled - attaching jigsaw guide rail

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.

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

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.

Jigsaw Crosscut Sled - cutting a slot

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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.

Jigsaw Cutting Station - jigsaw table 90 degree cut

Glue a wood strip along the first drawn line. Additionally, 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

Step 9. Attach an Adjustable Fence

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

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.

Jigsaw Cutting Station - aluminum angle bar
Jigsaw Cutting Station - aluminum angle bar
Jigsaw Cutting Station - aluminum angle bar

This is what the finished jigsaw cutting table looks like.

Jigsaw Cutting Station - jigsaw table 45 degree

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.

  1. Clamp the jigsaw cutting station to a workbench
  2. Set the table fence to the desired angle
  3. Insert the workpiece between the jigsaw guide track and the table 
  4. Secure the workpiece
  5. Mount the jigsaw in the track
  6. Slowly make the cut

NOTE: 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

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

Check out these Jigsaw Tips!

Jigsaw Cutting Station | Jigsaw Crosscut Sled - 45 degree cut
Jigsaw Cutting Station | Jigsaw Crosscut Sled - 45 degree cut

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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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

Jigs used for this project:

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