A couple of whiles ago when I posted my lumber rack, some of the LJ’s inquired about my panel jig. I figured that if I ever needed to replace it, then it would be right to blog it for you. I’m not going to take credit for this as I have seen it somewhere else in one of the many woodworking mags. Just can’t remember which one!
This jig is used lying on top of sawhorses or the bench to crosscut and rip large sheets of material. I say “material” because we’ve used it for sheetrock, plywood, MDF, hardboard, styrofoam, etc. It’s perfect for us small shop guys who don’t have cabinet saws with infeed/outfeed tables. It’s also quite portable as it takes up just 11’x8”x3” space when folded, but opens to a full 4’x8’ supporting the entire sheet.
It requires six 8’ 2×2’s, and 16 (of each) 1/4×20x2” bolts, washers and locknuts. Locknuts work best here as they will not eventually loosen and fall off. (Locknuts have the nylon insert inside them). Skill levels….basic at the most! This is easy to say the least! Take you about an hour.
2×2’s are expensive so I used 2×4’s ripped in half. You don’t have to be precise with this, but be sure to do all your drilling on the factory dimensioned side. So what you’ll have cut is four 8’ 2×2’s and four 4’ 2×2’s.
Mark the 4 footers at 4 1/2” from each end and again at 16 1/2” from each end. This is where you will drill four 1/4” holes thru each board.
Mark the 8 footers at 12” and again at 36” from each end. Drill four 1/4” holes thru each of these.
Now in each board, using a forstner (or spade) bit, drill halfway thru each 1/4” hole. Size your spade/forstner bit big enough to accomodate the washers. (I used a 7/8” bit on mine). It’s a good idea here to recess these bolts and nuts from the saw blade…but I’ve forgotted several times to reset my blade depth and have not only cut plywood, but also clean thru the 2×2 as well! So keep in mind that you need to adjust that blade depth before cutting.
All you need to do now is bolt it together. Don’t tighten the nuts too much though as to allow the unit to fold easliy. I’ve included pictures…they show the long ripping side followed by the short crosscut side, folded and stored.
-- Bob Vila would be so proud of you!
21 comments so far
horob
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12 posts in 607 days
posted 597 days ago
Great idea! Thanks for posting the details.
mrtrim
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1698 posts in 775 days
posted 597 days ago
great idea dadoo !
GaryK
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9521 posts in 883 days
posted 597 days ago
That’s a great idea!
I like that you can just flip it over to go from crosscutting to ripping.
-- Gary, East TX -- The longest journey begins with a single step.
GMoney
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147 posts in 698 days
posted 597 days ago
Thank you, I’ll be making one of those.
-- Greg, CT
SPalm
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948 posts in 776 days
posted 597 days ago
Now that is down right clever. Thanks.
-- Stevethepeeve -- I'm no rocket surgeon
Bob #2
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3039 posts in 916 days
posted 596 days ago
A great idea for cramped quarters. It’s a space saver too.
Well thought out Dadoo!
Bob
-- A mind, like a home, is furnished by its owner
Lee A. Jesberger
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3710 posts in 874 days
posted 596 days ago
Hey Dado;
That’s a great idea, and a very good blog on making it.
Good thing I didn’t see this in the article you mention or ezee-feed may never have come about! LOL
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
motthunter
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2079 posts in 693 days
posted 596 days ago
slick!
-- making sawdust....
Grumpy
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14920 posts in 745 days
posted 596 days ago
Thanks for sharing Dadoo.
-- Grumpy - "Always look on the bright side of life"- Monty Python
Scott Bryan
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20651 posts in 716 days
posted 596 days ago
Nice jig Dadoo. I will have to try this. It sure beats trying to position 2×4s on the bench or floor to support the plywood while cutting.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
jcees
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552 posts in 693 days
posted 596 days ago
Sweet! That one takes up less room than mine. I likey.
always,
J.C.
-- "Imagination is more important than knowledge" -- Albert Einstein
John Gray
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1753 posts in 780 days
posted 596 days ago
Great idea thanks.
-- Only the Shadow knows....................
mlfdfire
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10 posts in 564 days
posted 559 days ago
I really like this jig I will have to build one for my shop. I always struggled cutting 4×8 sheet stock by my self. thanks for the pics and info.
PG_Zac
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152 posts in 283 days
posted 279 days ago
Just tooooo clever.
Thanks. I like seeing innovative ideas take shape
-- I may be schizophrenic, but at least I have each other.
Peter O
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1021 posts in 769 days
posted 262 days ago
This is great Dadoo! I’m going to build one very soon.
-- http://www.north40custom.com -- http://north40studios.etsy.com --
David_Bethune
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243 posts in 287 days
posted 262 days ago
That really is neat. Wish I had a bigger shop.. I’d make one..:)
Tony
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811 posts in 924 days
posted 262 days ago
Just what I needed, thanks for posting it.
-- Tony - All things are possible, just some things are more difficult than others! - SKYPE: Heron2005 (http://www.poydatjatuolit.fi)
SteveMO
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42 posts in 303 days
posted 262 days ago
Nice piece of work. Will add to my list of weekend projects. Thanks for the tip.
MNbuzzdust
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99 posts in 246 days
posted 233 days ago
This is awesome! Thanks for posting it. You made my day.
mtnwild
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2013 posts in 422 days
posted 233 days ago
That is smart, very cool!
-- mtnwild (Jack), It's not what you see, it's how you see it.
de1946
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2 posts in 277 days
posted 232 days ago
I made one and used it immediately. I was cutting Sheetrock and I used plastic saw horses. I had to screw 2X6’s to the top so that I could clamp the gig. This worked out great. Thanks for the plans.
-- Richard A. Morano, Sr.