3D Stars #2: Compound Angle Cutting Jig with Hold Downs for a Radial Arm Saw

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Blog entry by Aggie69 posted 02-13-2013 02:00 AM 9988 reads 5 times favorited 4 comments Add to Favorites Watch
« Part 1: Program for Calculating Dimensions and Angles for 3D Stars Part 2 of 3D Stars series Part 3: Making 3-D Stars »

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 clear of the blade while your’re cutting!

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 workpiece. 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.

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. In the picture below, the saw guard has been removed and the saw carriage raised for picture clarity

4 comments so far

View jap's profile


1251 posts in 2966 days

#1 posted 02-13-2013 02:50 AM

nice jig

-- Joel

View NormG's profile


6508 posts in 3915 days

#2 posted 02-13-2013 03:31 AM

Great idea and looks wonderful

-- Norman - I never never make a mistake, I just change the design.

View Nate Meadows's profile

Nate Meadows

1132 posts in 3118 days

#3 posted 02-13-2013 04:17 AM

This is awesome! You have a gifted Brain!


-- "With a little bit of faith, and some imagination, you can build anything!" Nate

View Diggerjacks's profile


2328 posts in 4050 days

#4 posted 02-13-2013 05:57 PM

Hello Aggie69

A very nice and ingenius jig

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

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