Panel Cutting Jig

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Blog entry by Dadoo posted 04-06-2008 08:08 PM 18265 reads 52 times favorited 22 comments Add to Favorites Watch

A couple of whiles ago when I posted my lumber rack, some of the LJ’s inquired about my panel jig. I figured that if I ever needed to replace it, then it would be right to blog it for you. I’m not going to take credit for this as I have seen it somewhere else in one of the many woodworking mags. Just can’t remember which one!

This jig is used lying on top of sawhorses or the bench to crosscut and rip large sheets of material. I say “material” because we’ve used it for sheetrock, plywood, MDF, hardboard, styrofoam, etc. It’s perfect for us small shop guys who don’t have cabinet saws with infeed/outfeed tables. It’s also quite portable as it takes up just 11’x8”x3” space when folded, but opens to a full 4’x8’ supporting the entire sheet.

It requires six 8’ 2×2’s, and 16 (of each) 1/4×20x2” bolts, washers and locknuts. Locknuts work best here as they will not eventually loosen and fall off. (Locknuts have the nylon insert inside them). Skill levels….basic at the most! This is easy to say the least! Take you about an hour.

2×2’s are expensive so I used 2×4’s ripped in half. You don’t have to be precise with this, but be sure to do all your drilling on the factory dimensioned side. So what you’ll have cut is four 8’ 2×2’s and four 4’ 2×2’s.

Mark the 4 footers at 4 1/2” from each end and again at 16 1/2” from each end. This is where you will drill four 1/4” holes thru each board.

Mark the 8 footers at 12” and again at 36” from each end. Drill four 1/4” holes thru each of these.

Now in each board, using a forstner (or spade) bit, drill halfway thru each 1/4” hole. Size your spade/forstner bit big enough to accomodate the washers. (I used a 7/8” bit on mine). It’s a good idea here to recess these bolts and nuts from the saw blade…but I’ve forgotted several times to reset my blade depth and have not only cut plywood, but also clean thru the 2×2 as well! So keep in mind that you need to adjust that blade depth before cutting.

All you need to do now is bolt it together. Don’t tighten the nuts too much though as to allow the unit to fold easliy. I’ve included pictures…they show the long ripping side followed by the short crosscut side, folded and stored.





-- Make Woodworking Great Again!

22 comments so far

View horob's profile


12 posts in 5166 days

#1 posted 04-06-2008 08:44 PM

Great idea! Thanks for posting the details.

View mrtrim's profile


1696 posts in 5333 days

#2 posted 04-06-2008 08:59 PM

great idea dadoo !

View GaryK's profile


10262 posts in 5441 days

#3 posted 04-06-2008 09:10 PM

That’s a great idea!

I like that you can just flip it over to go from crosscutting to ripping.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View GMoney's profile


158 posts in 5256 days

#4 posted 04-06-2008 09:19 PM

Thank you, I’ll be making one of those.

-- Greg, CT

View SPalm's profile


5338 posts in 5335 days

#5 posted 04-06-2008 09:37 PM

Now that is down right clever. Thanks.

-- -- I'm no rocket surgeon

View Bob #2's profile

Bob #2

3810 posts in 5474 days

#6 posted 04-06-2008 10:35 PM

A great idea for cramped quarters. It’s a space saver too.
Well thought out Dadoo!


-- A mind, like a home, is furnished by its owner

View Lee A. Jesberger's profile

Lee A. Jesberger

6883 posts in 5432 days

#7 posted 04-06-2008 10:40 PM

Hey Dado;

That’s a great idea, and a very good blog on making it.

Good thing I didn’t see this in the article you mention or ezee-feed may never have come about! LOL


-- by Lee A. Jesberger

View motthunter's profile


2141 posts in 5252 days

#8 posted 04-06-2008 11:25 PM


-- making sawdust....

View Grumpy's profile


26811 posts in 5304 days

#9 posted 04-07-2008 01:20 AM

Thanks for sharing Dadoo.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Scott Bryan's profile

Scott Bryan

27248 posts in 5275 days

#10 posted 04-07-2008 02:49 AM

Nice jig Dadoo. I will have to try this. It sure beats trying to position 2×4s on the bench or floor to support the plywood while cutting.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View jcees's profile


1079 posts in 5252 days

#11 posted 04-07-2008 04:24 AM

Sweet! That one takes up less room than mine. I likey.


-- When one tugs at a single thing in nature, he finds it attached to the rest of the world. -- John Muir

View John Gray's profile

John Gray

2370 posts in 5338 days

#12 posted 04-07-2008 05:45 PM

Great idea thanks.

-- Only the Shadow knows....................

View mlfdfire's profile


10 posts in 5123 days

#13 posted 05-14-2008 03:52 PM

I really like this jig I will have to build one for my shop. I always struggled cutting 4×8 sheet stock by my self. thanks for the pics and info.

View PG_Zac's profile


373 posts in 4842 days

#14 posted 02-18-2009 05:48 PM

Just tooooo clever.

Thanks. I like seeing innovative ideas take shape

-- I may be schizophrenic, but at least I have each other.

View Peter Oxley's profile

Peter Oxley

1427 posts in 5327 days

#15 posted 03-07-2009 08:36 AM

This is great Dadoo! I’m going to build one very soon.

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