|Project by Aggie69||posted 02-10-2013 07:08 PM||6488 views||4 times favorited||7 comments|
I have developed a program to calculate cutting dimensions and angles for building 3 dimensional stars. 3-D Star Blog. Trying to cut narrow pieces for the stars at steep angles and bevels on my radial arm saw required some assistance.
I designed a simple jig that would clamp into the table in the fence joint, anywhere along the fence joint. You can make angle cuts to ~60 degrees left or right while leaving the saw carriage arm to run straight back and forth. You can bevel the saw carriage to ~70 degrees to create compound cuts on small pieces. Best of all, you can clamp down the workpiece and keep your hands way clear of the blade while your’re cutting! My normal 10” saw blade wouldn’t clear the top of the jig on bevels from about 20 degrees to 70 degrees. Changing out the blade to a 7-1/4” blade worked great.
Not wanting to cut up my jig everytime I make a cut, I use a piece of sacrificial 1/8” hardboard (Masonite) underneath the piece being cut. I used a mini-T track fastened into the wood angle arm and 1/4” x 20 hex head bolts and knobs for the hold down hardware (purchased from Peachtree Woodworking Supply). The clamps were homemade from 1” x 1/4” x 4”, 5”, or 6 “ash with 1/4” wide slots in the center. The ends of the hold downs were soft pine to reduce surface dinging of the held down wood. The pivot point bolt and the circle hold down bolt are 1/4” x 20 “elevator” bolts (flat head, ~1” dia). The jig table is MDF, the wood angle arm is ash, and the fence is pine.