How to Make a Table Saw Fence

If your table saw requires a fence then it’s easy to construct one that will enable you to cut wood with efficiency. The best thing about this model is that there is no room for sawdust to wedge into and it occupies less space on the table.

Most tables saw come with fences that do not run the full length of the table.   It makes it difficult to make quality end product as the table bend away from the blade when ripping the wood producing rough cuts.  The old fence may be modified by using part of the old fence, therefore, making it easier for the whole fence to glide smoothly.

You can make a table saw fence at home in more manageable steps.   The following tips will enable you in this process.

Required Materials

The first step is to establish the materials you need to make the new fence.  You should also have the tools you need to do this job before embarking on it.   Get prepared first to avoid a situation where you have partially disassembled your table saw only to realize that you do not have specific equipment.   Below is a list of all your requirements.

  • Table saw with an original fence
  • T-Square
  • Two bolts, nuts, and washers (you can use the two wing nuts and washers that were on the original fence.
  • Scrap wood or melamine for the fence runners or scrap plywood.
  • Drill
  • Drill bits, countersink and fastening screws.
  • Tape Measure
  • Pencil
  • Calipers (Optional)
  • Nail gun / Panel Pins and a Hammer

Disassembling the Original Fence and Marking New Runner

Take measurements of the length of your table saw table and cut two boards of the same length from the materials of your choice.  The list above will guide you in making your favorite selection.

  • Make sure the material is adequately finished to prevent any wastage,
  • To disassemble your original table saw fence, remove the two wing nuts and the washers from the back of the fence. Remove the runners and the bolts too.  The bolts washers and the bolts are reusable in making your new fence.
  • Square your new fence runner to the fence mechanism using your T-square. The new runners should be marked where the holes will be drilled.

Drilling the Holes and Sinking the Bolts

  • Using the drill or drill press, drill a pilot hole and then the holes for the bolts on the marked spots on the new runners. These are the holes where you will insert your bolts.   A drill press will make square holes.  With the hand drill, you will achieve the same results.
  • After drilling the holes for the bolts, enlarge the holes to give room for the bolt to sink into the runner. It thus ensures that you get perfect cuts when the fence is finished.   You can use the drill to enlarge the holes guaranteeing that you do not make the holes too wide for the bolts and the washers, just the required size.  It will allow the head of the bolt to be sunk into the board with ease.TableSaw Fence

Attaching the New Runner and Back Plate

  • Unite the old fence mechanism with the new fence runner square to the blade using the bolts, washers and wing nuts that were fixed to the original fence. You can opt to use new bolts, washers, and nuts if you so desire.
  • At the back of the fence cut a piece of wood of your desired width, but which is wide enough to hold your push sticks. Ensure when cutting the height of the board, it is big enough to screw to the fence runner and also runs along the back edge of the fence.
  • Once done, drill pilot holes, countersink and fasten it to the fence runner with screws. Where melamine is used, make sure you drill a pilot hole in this too as it is easily breakable. It should be square.   Attach it to the second board in the same way to the plate at the back of the fence.

Related  :Build-Table-saw-sled Step by Step

Attaching the Front Plate

Front plates should be the same size as those attached at the back.

  • Cut a piece of wood to the exact width as the plate at the back, the height to match with the height of your fence.
  • Once the boards are ready with correct width and height, you will attach them just as you did at the back.
  • Drill the pilot holes, countersink and attach with screws. Ensure the fence runner is square to the blade and that the other board is rectangular.

Capping of the Fence

Your fence can be capped in the following ways:

  • Measure the width and length of the fence and only cut a piece of wood to the dimensions and attach it to the top of the fence.
  • Cut a piece of wood to fit the inside of the fence and attach it leaving a space to put push sticks to make them easily accessible. In this way, measure the inside distance using a machinists calipers.
  • Take this measurement to a piece of wood and rip it to the correct width. Measure the length of the fence and cut the board of this length.
  • Use a nail gun to attach the piece of wood at the front. Do the same to the back as well as one side of the fence.  It will make it stronger and durable.   You may opt to attach to other places if necessary.

Conclusion  

From the demonstration above, you are more enlightened on how you can have maximum benefits of your table saw.  You will never be disappointed as long as you follow the above procedure.  You will have a new and improved table saw fence that will serve you for many years. You are now guaranteed of perfect quality cuts.  Making long rip cuts will now be more comfortable as you do not move out of alignment. Enjoy maximum production with this discovery of table saw fence.