Custom Fence design help for bandsaw/router table

  • Advertise with us

« back to Power Tools, Hardware and Accessories forum

Forum topic by Clobby posted 11-02-2016 03:17 PM 392 views 0 times favorited 3 replies Add to Favorites Watch
View Clobby's profile


16 posts in 721 days

11-02-2016 03:17 PM

Topic tags/keywords: fence aluminum

I have a 2’x2’‘3/4” milled aluminum slab at work that the guys will cut, drill, mill for me for a couple custom fences.

I have a 14” bandsaw with only a 5.25” resawing capability for now, plus a 12a router that I want to make fences for.

I was thinking 3” wide for each of the fences. I just need some dimensions to cut for now, so I can rig up something true enough to do some resawing for a project. I can finish the build later on, but should it be higher, shorter? Thanks!

-- Wood working newbie, IT Pro for 15 years, ask away for computer help to help repay all the noob wood working questions.

3 replies so far

View Kelly's profile


2092 posts in 3093 days

#1 posted 11-03-2016 02:26 AM

If I am understanding what you want to do, that’d be one beefy fence. Aint nuthin wrong with that, within reason. Consider, for example, the one four my 14” [with a riser block] is just the usual thin wall aluminum channel and it does not defect at all.

Next, jump to my five hundred pound cabinet saw. I have two fences for it. One is a Unifence, which is about three inches wide, but it’s in an L shape, so it’s only three inches [or so] at the bottom and that portion is only about 1/4” thick. The other fence is for jigs and such and is a couple inches thick and about four inches tall.

Maybe a bit more information would help. Are you just going to have a three inch wide, four inch tall, [approx.] twenty inch long chunk of aluminum for a fence?

Keep in mind, as you crank the capacity of the saw, you’ll get greedy for each inch you can grab for material runs. If you lose three inches between the blade and the left side of the saw, you’ll start wanting some of it back. For a fence tall enough for re-saw, I believe 3/4” would be MORE than adequate. A fence 3/8” would probably do. I use 3/4” plywood for ten inch cuts.

That help any?

View HokieKen's profile


6298 posts in 1287 days

#2 posted 11-03-2016 04:23 PM

I’d go with the 3” height but have them add some threaded holes to the BS fence so you can bolt on a piece of taller ply or MDF for the situations where you may need it and have them mill some slots in the router fence and hog out a section in the middle for the bit. Then you can add some sliding fences that will allow you to close the fence right up to the bit when needed. You may also want the option of adding a tall face to the router fence for working on the edges of tall boards. Maybe even go ahead and have them make you a few sets of faces to go on the fences. With aluminum, 1/4-3/8” thick would be plenty for the faces.

-- Kenny, SW VA, Go Hokies!!!

View Loren's profile


10477 posts in 3796 days

#3 posted 11-03-2016 04:29 PM

2-3” tall is fine. There’s enough fence to support
tilted work and the fence isn’t so tall you have
to leave the upper guides set way high whenever
the fence is close to the blade.

For resawing I often attach an auxiliary fence
about 6” tall. Depending on the saw and blade
I might put a curve on the attachment to allow some
degree of steering in resaw cuts.

Have your say...

You must be signed in to reply.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics