Panel saw

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Project by modal posted 11-04-2010 06:38 PM 18937 views 12 times favorited 16 comments Add to Favorites Watch

Single sheet of plywood cut down the middle. Thompson rails were 5’, just enough to cover the 4’ travel left over from earlier project. Bottom pillow blocks actually two oak stop blocks so that rails can’t slip out of top pillow blocks. Footer consists of 2×4 and 1×6 sandwiched to create a pocket, rollers in pocket made from old roller skates were a bad idea from an accuracy standpoint. Counterweight is a 3”x12” iron boat anchor I had made from round bar stock that was sitting on my garage stoop for about 10 years. Works good for plastic and wood panels. Counterweight pulley support blocks are 2” aluminum tube with hole on only one side left over from greenhouse construction. Any tubing should work. By mounting the oak blocks at the base first, the precise location of the holes could be determined with a pair of calipers and a T-square. Wheels were added to aid in transport. A sacrificial board was mounted beneath the saw, this served two purposes, bowed strips no longer would get stuck while rolling into place, and the scribe from the saw on the sacrificial strip was handy for alignment on irregular pieces.

-- Ed Kimble, Columbia City, Indiana,

16 comments so far

View CharlieM1958's profile


16292 posts in 5271 days

#1 posted 11-04-2010 07:01 PM

Very nifty!

-- Charlie M. "Woodworking - patience = firewood"

View rainman's profile


54 posts in 4216 days

#2 posted 11-04-2010 07:02 PM

Wow , really nice job! I’ve always wanted one , just never thought of building it my self. Thats my kind of project. Really well done!!!!!!!!!!

-- So much wood, So little time

View Beginningwoodworker's profile


13345 posts in 4725 days

#3 posted 11-04-2010 07:03 PM

Thats a neat idea.

View Jamie Speirs's profile

Jamie Speirs

4168 posts in 3909 days

#4 posted 11-04-2010 07:05 PM

Nicely done.
I love my panel saw.

-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View GaryL's profile


1099 posts in 3883 days

#5 posted 11-04-2010 07:08 PM

Nice build! Are there adjustments for tuning the cut, ie. square.?

-- Gary; Marysville, MI...Involve your children in your projects as much as possible, the return is priceless.

View mafe's profile


13076 posts in 4141 days

#6 posted 11-04-2010 07:39 PM

So cool. Thats really a brilliant simple way to solve it.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect.

View RexMcKinnon's profile


2593 posts in 4248 days

#7 posted 11-04-2010 08:36 PM

Cool, nice design.

-- If all you have is a hammer, everything looks like a nail!

View Jim Jakosh's profile

Jim Jakosh

26059 posts in 4158 days

#8 posted 11-04-2010 09:01 PM

Very nice panel saw. I’ll bet it rides nice on those Thomson rails, too.

Thanks for sharing….....

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View NBeener's profile


4816 posts in 4226 days

#9 posted 11-04-2010 09:03 PM

Sweet !

Is there anybody that wouldn’t love having one of these, in their shop ?

(Okay, you Festool Track Saw owners. Feel free to sit this one out <grin>)

-- -- Neil

View jockmike2's profile


10635 posts in 5299 days

#10 posted 11-04-2010 11:47 PM


-- (You just have to please the man in the Mirror) Mike from Michigan -

View HalDougherty's profile


1820 posts in 4289 days

#11 posted 11-05-2010 12:09 AM

Swap a router for the saw and you’ve got a great dado cutter as well. If you mount the edge board to be routed on the edge of the router cut, you’ve got a jointer to get one edge straight on a crooked board.

-- Hal, Tennessee

View Mark Shymanski's profile

Mark Shymanski

5623 posts in 4765 days

#12 posted 11-05-2010 12:14 AM

Great idea, looks like a really useful tool.

-- "Checking for square? What madness is this! The cabinet is square because I will it to be so!" Jeremy Greiner LJ Topic#20953 2011 Feb 2

View gary351's profile


97 posts in 3848 days

#13 posted 11-05-2010 01:28 PM

Look’s very useful ! Welcome to LJ’s

-- A poor man has poor way's

View helluvawreck's profile


32122 posts in 3919 days

#14 posted 11-05-2010 01:35 PM

That’s a nice little rig. Good work!

-- helluvawreck aka Charles,

View Condor1's profile


64 posts in 4030 days

#15 posted 11-05-2010 06:02 PM

I always like to see a junkyard dog at work. It’s amazing what a man can create if he has a need and puts his mind to it. Great job!

-- There are times when a mistake is remembered as your best work.

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