How To Make a Track Saw?

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Forum topic by tool_junkie posted 06-03-2013 04:36 AM 21510 views 2 times favorited 26 replies Add to Favorites Watch
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324 posts in 2524 days

06-03-2013 04:36 AM

I would like to use my Bosch circular saw with a track for precise cuts. But in my view, the options currently available on the market are extremely over priced, like the Eureka Zone track system.

I know fellow LJs have made similar setup in the past but the downfall of the ones I have come across so far, is that they use a miter bar attached to the saw base that rides in a dado’d track. This makes the saw not useable without the track.

The commercially available systems use the opposite approach where the dado is in the saw base attachment and the miter bar is on the track. Has someone built a similar system?

For my track saw system, I would like to use aluminum track similar to what Eureka Zone and the likes use in their system. Does anyone know where to buy such a track for cheap? I am sure there must be a wholesale type supplier that wont charge as much.


26 replies so far

View Loren's profile


10377 posts in 3642 days

#1 posted 06-03-2013 04:41 AM

Not happening. Bite the bullet and buy the Eurekazone.

Aluminum extrusions are not that cheap, even in common
industrial profiles. Steel is a lot cheaper by weight but
cannot be as easily extruded and is too heavy anyway.
Anodizing has real costs and the dies to make an extrusion
like the Ezsmart are substantial.

Look at 80-20 extrusions if you want to fuss with
making your own system. You could make a panel
saw from it…. track saw, I think not.

View waho6o9's profile


8187 posts in 2571 days

#2 posted 06-03-2013 04:50 AM

View Tomj's profile


204 posts in 2376 days

#3 posted 06-03-2013 06:16 AM

Has anyone tried tried the Grizzly track saw yet?

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Jeremy Greiner

568 posts in 2766 days

#4 posted 06-03-2013 06:46 AM

The wood whisperer did a review which basically said that it’s miles better than a regular circular saw, but not as good as the festool saw, mostly in the dust collection area I recommend the video, while marc may be a festool fanatic (I’m just jealous) he does give an honest review of the saw.

But you don’t really need a full track system, just a piece of wood that’s straight, glued or screwed to a piece of plywood gives you a good enough track, I like my buddy hjt’s track it works well for him, and I have something similar.


-- Easy to use end grain cutting board designer:

View Tomj's profile


204 posts in 2376 days

#5 posted 06-03-2013 06:59 AM

I have a shop made track and an old Craftsman circular saw, but I would really like something with dust collection. I might look more into the Grizzly.

View Gene Howe's profile

Gene Howe

10479 posts in 3423 days

#6 posted 06-03-2013 11:51 AM

Takes me 30 seconds to remove or attach the bar on the base of my Skil 77. Small price for the improved accuracy and ease of cut alignment. REALLY small price when compared to the cost of a commercial jig that does the same thing.

-- Gene 'The true soldier fights not because he hates what is in front of him, but because he loves what is behind him.' G. K. Chesterton

View redSLED's profile


790 posts in 1887 days

#7 posted 06-03-2013 12:49 PM

I would like to do the same.

I think the trick is to put a dado’d track in the circular saw custom base and the guide bar on the custom track. Then you could still use your saw for other stuff. I think this DIY option is still do-able – my eyes are still open for the right (simple design). Still would have to find a wide-ish aluminum track from a metal supplier or somewhere – then to stick on some thin ‘router pad’ material on the bottom (no clamping required!)

-- Perfection is the difference between too much and not enough.

View Loren's profile


10377 posts in 3642 days

#8 posted 06-03-2013 02:26 PM

There’s the Pharaoh guide:

View waho6o9's profile


8187 posts in 2571 days

#9 posted 06-03-2013 02:52 PM

The best one on the planet, oh yeah.

View toolie's profile


2121 posts in 2623 days

#10 posted 06-03-2013 03:41 PM

i really like that festool copy cat in waho6o9”s you tube link. so much so that i’m now on teh CL prowl for a used 7 1/4” circular saw to set up as a dedicated “track” saw.

-- there's a solution to every just have to be willing to find it.

View tool_junkie's profile


324 posts in 2524 days

#11 posted 06-03-2013 04:36 PM

Jeremy, I already have the guide you mentioned in your post. I am just looking for an even more precise guide.

Since starting this thread last night, I have been thinking of an idea of mounting an 8 foot long (or shorter) 1/2” high x 3/4” wide aluminum bar (if there is such a thing) on a piece of 1/4” ply and mounting a thick cutting board on the base of the saw with a 3/4” wide and 1/2” deep dado routed in it. Would that work? I think the main concern would be to ensure the straightness of the aluminum bar.

What do you guys think?

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3168 posts in 3226 days

#12 posted 06-03-2013 04:42 PM

I bought the Scheppach Track Saw when it was on sale through WOOT!. So far it has worked well but I have only cut up one sheet of 3/4 plywood and half of a 1/2 inch sheet while preparing to build some cabinets for the shop.

The Scheppach cs55 track saw is identical to the Grizzly model. I also bought the Grizzly 55 inch track and attachment kit. All fit and work as one unit with no problems encountered.

-- Handcrafted by Mike Henderson - Channelview, Texas

View Woodknack's profile


11608 posts in 2375 days

#13 posted 06-03-2013 04:53 PM

I think your cutting board idea will work, just make sure the cutting board is flat. You’ll lose some depth of cut but everything is a trade-off.

-- Rick M,

View tool_junkie's profile


324 posts in 2524 days

#14 posted 06-03-2013 05:07 PM

I forgot to ask, does anyone know of sources for buying aluminum bars, as I mentioned in my post above?

View PurpLev's profile


8535 posts in 3643 days

#15 posted 06-03-2013 05:16 PM

-- ㊍ When in doubt - There is no doubt - Go the safer route.

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