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Custom Fence Extension for Miter Saw

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Project by FloridaArt posted 756 days ago 7807 views 15 times favorited 5 comments Add to Favorites Watch

June, 2012—On a recent project I needed to cross-cut multiple pieces to the exact same length. Measuring and cutting each piece individually got old fast. So I decided to build an extension fence for my DeWalt miter saw. The fence is on the left side of the saw. Two pieces are store-bought from our local Woodcraft store: The Incra 36-inch T-Track Plus with Adjustable Scale (Woodcraft #142582), and the Kreg Production Stop (Kreg #KMS7800).

On the left side of the saw is a hole ready for a machine screw. I found a screw to fit the thread in my junk pile. You can see this in the second photo. Also, the saw has a small lip just under that screw, running along the side of the saw. I decided to use the screw and the lip to support the fence and connect it to the saw. The third and fourth photo show the fabricated support piece with a slot. The slot allows the fence to be quickly attached or removed from under the screw on the saw. This supports the right side of the fence. The left side of the fence is supported by a removable support elevator, doweled into the hinged leaf of my miter table.

The fence itself is a glue up of planed pallet lumber, probably pine. A rabbit on the bottom makes a tight joint with the half-inch plywood base. A rabbit on the top is needed to provide clearance for the Kreg Production Stop (in the rear of the stop, where it drops down a fraction below the Incra T-Track). Lastly, a small piece of wood is attached to the underside of the working end of the Stop. This will prevent small work from sliding under the Stop.

Finally I adjusted the rule (scale) that comes with the Incra T-Track. Between the slide-able track rule and the adjustable red-line cursor lens in the Kreg Production Stop, it is very easy to set this up with high accuracy. And the Production Stop, when tightened with the knob, is very secure. It does not bend nor wobble. This will be great for repetitive cuts!

The rule / scale that comes with the Incra is really too short. This is because the first seven inches or so are not used because the track does not extend to the right all the way to the blade. Not a big deal, but it would have been nice had the 36-inch Incra T-Track come with a 48-inch rule.

To cut pieces less than 8-inches in length, the Associate at the Woodcraft store gave me this tip: Cut a piece of wood accurately to 10-inches. Then use that as a spacer between the Stop and the work. So if I need a 4-inch piece, I would set my stop to 14-inches and butt the work up against the 10-inch spacer, which is in turn butted against the Stop. Easy!

The entire fence is coated with water-based semi-gloss polyurethane. I am very happy with the final result, and I expect this will make my use of this miter saw much more enjoyable!

-- Art | Bradenton, Florida





5 comments so far

View ratchet's profile

ratchet

1283 posts in 2385 days


#1 posted 756 days ago

Nice one. Thats should really help with accuracy.

View Greg The Cajun Box Sculptor's profile

Greg The Cajun Box Sculptor

4934 posts in 1906 days


#2 posted 756 days ago

I ti will make a world of difference and repetitive accuracy. Several years ago I bought the Kreg miter track system and mounted it to my miter table. I get so much use out of it. I did the same with the spacer block…except I made mine 15”.

-- Every step of each project is considered my masterpiece because I want the finished product to reflect the quality of my work.

View Dusty56's profile

Dusty56

11638 posts in 2286 days


#3 posted 756 days ago

Nice looking project and a great write up , including the tips : )
I can’t tell from your pictures , but normally there should be some space below the flip stop to allow sawdust to escape so it doesn’t build up at the stop and throw your measurement off.

-- I'm absolutely positive that I couldn't be more uncertain!

View Roger's profile

Roger

14114 posts in 1402 days


#4 posted 755 days ago

Very good. You will be very happy you did that

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View javaboy's profile

javaboy

102 posts in 732 days


#5 posted 728 days ago

Great idea and execution! I’ve been mulling over doing something like that for my chop saw. Thanks for sharing!

-- Sow justice, reap peace

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