This project was built and designed by Stan Sullivan. It’s a practical setup for building your own rip fence and a clever alignment jig that ensures accurate, parallel cuts on the table saw—something every woodworker needs.
With a focus on safety, precision, and repeatability, Stan shows how you can get reliable results without expensive commercial tools. The jig is made from scrap wood and a few basic parts, making it accessible for any home workshop.
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Why Fence Alignment Matters
A misaligned rip fence is one of the most common issues on a table saw. If the fence isn’t perfectly parallel to the blade, it can lead to inaccurate cuts, poor joinery, or worse—kickback.
Stan experienced this firsthand with a factory rip fence that didn’t lock down straight. That frustration led him to build a homemade fence paired with a simple jig that makes alignment fast and repeatable.
Understanding the Basics
A rip fence guides your workpiece along the blade, so its alignment is critical. Even a small offset between the front and back of the fence can create binding and kickback, especially when ripping long boards.
Stan explains that measuring from a specific tooth on the saw blade—one that points in the same direction as the fence—is the best way to judge alignment. By checking this distance at both ends of the fence, you can fine-tune its position for perfect parallelism.
Building the Homemade Jig
The alignment jig uses common, inexpensive parts. The key components include:
- A wooden yardstick or ruler
- Scrap wood blocks
- A threaded insert and thumb screw
Stan cuts the jig body from leftover furring strips and mounts the yardstick between two adjustable blocks. Once the desired measurement is set, tightening the thumb screw locks the jig in place.
The idea is simple: place the jig next to the blade, set it to your desired cut width, and slide the fence up to meet the jig. It eliminates guesswork and speeds up the setup process.
Using the Jig on the Table Saw
To align the rip fence:
- Measure the distance from the blade to the miter slot.
- Add your desired rip width to that distance and set the jig accordingly.
- Move the rip fence until it just touches the jig at both the front and back ends.
- Lock the fence in place and double-check your measurements before cutting.
Stan finds that the fence usually gets close on its own and only needs a slight adjustment. This jig ensures it stays parallel—especially helpful when switching between different cut widths during a project.
Benefits of a Homemade Approach
Building your own fence and alignment jig might seem minor, but it has a big impact in the shop. You save money, reduce error, and gain better control over your setup.
Stan’s method shows that precision tools don’t have to be expensive. With a few offcuts and simple hardware, you can build something that boosts both safety and confidence at the saw.
Practical Tips and Lessons Learned
Throughout the project, Stan shares lessons that will resonate with woodworkers. Sometimes, the best order of operations isn’t clear until halfway through a build. Mistakes like cutting a piece too soon or overlooking alignment steps can happen—but they’re all part of the learning curve.
His approach is relaxed and realistic. Instead of stressing over perfection, he adapts with clamps, fine-tuning, and creative fixes. The alignment jig itself is a perfect example of solving a recurring problem with a straightforward solution.
Alternative Tools and Considerations
While Stan’s jig works well, he acknowledges that there are other ways to achieve the same goal. Some woodworkers use dial indicators, digital calipers, or commercial alignment blocks.
However, those tools can be pricey and aren’t always necessary for typical shop work. Stan’s solution is fast, accurate, and made from materials most woodworkers already have on hand.
A Worthwhile Upgrade for Any Table Saw
This project might not look flashy, but it has major value for anyone serious about improving their table saw setup. Aligning your fence the right way improves every cut that follows—from rough rips to final dimensions.
If your current fence doesn’t lock parallel, or if you want to double-check your setup quickly, this jig offers a low-cost fix. It’s one of those shop-made tools you’ll end up using more than you expected.
Get Stan’s plans here: https://www.simplyeasydiy.com/2014/02/in-previous-post-and-video-i-built.html.