This project was built and designed by Rob from Let’s Make Things. It’s a simple yet highly effective jig that helps woodworkers make clean, square cuts with just a circular saw and a few affordable materials.
Ideal for beginners or anyone without a table saw, this jig provides a reliable solution for breaking down lumber and sheet goods accurately. With a smart setup and minimal investment, Rob shows how to make woodworking more accessible for all skill levels.
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Why Clean Cuts Matter
Accurate cutting is one of the most important skills in woodworking. It directly impacts the fit, look, and safety of any project.
Rob’s jig addresses the common struggle of getting straight cuts with a handheld circular saw. By running the saw along a fixed fence, the jig keeps the blade square and eliminates wandering—especially helpful when working without a full shop setup.
Materials and Jig Design
The jig consists of two main components: a hardboard base and a wooden fence. The hardboard acts as a stable platform, while the fence guides the circular saw along a consistent path.
For added durability, Rob includes a strip of Unistrut (a type of metal channel) on the fence’s edge. This optional upgrade gives the saw base a smooth, slick track and helps the jig last longer. However, the jig works just fine without it if you prefer to keep it all wood.
Prepping the Base and Fence
Rob starts by selecting a piece of hardboard with at least one clean, factory-cut edge. This edge will be used to align the fence, which is critical for creating perfect 90-degree cuts.
A line is marked along the base for positioning the fence. To prevent damage to the work surface during cuts, riser blocks can be added underneath the jig, raising it slightly off the table or bench.
The fence is made from a straight piece of stock wood—something that requires a bit of hunting at the store to find one without twists or bows. Using a level or straightedge helps confirm its accuracy before attaching it.
Assembling the Jig
Once the fence is positioned, it’s clamped in place and double-checked with a carpenter’s square to confirm the angle. When everything is square, it’s screwed down with countersunk screws to keep the surface smooth and avoid interference with the saw blade.
Screw placement is important—none should be in the saw’s path. Rob emphasizes the need to plan screw locations carefully so they don’t dull the blade or split the jig.
If using the optional Unistrut edge, it’s secured along the fence now to give the saw a slick, consistent surface to ride against.
Using the Jig Effectively
To make a cut, simply clamp the jig to the workpiece. The saw base rides along the fence, guiding the blade through the wood in a straight line.
This setup is useful for crosscutting lumber to length, trimming rough edges, or breaking down sheet goods. It’s also excellent for smaller or awkward pieces that might be hard to cut safely with just the saw alone.
Because the jig acts as a physical guide, it improves both the safety and accuracy of the cut. Beginners, especially, will appreciate the added control and consistency it provides.
Tips for Best Results
- Clamp Everything Securely: Movement ruins accuracy, so clamp the jig firmly to the material before cutting.
- Double-Check the Fence: A perfectly straight and square fence is the foundation of this jig. Don’t rush that step.
- Mind the Screws: Keep screws away from the cut line and always countersink them.
- Use Riser Blocks: Elevating the jig slightly protects your table or bench from the saw blade.
- Test First: Try a few test cuts on scrap wood before moving to your project materials.
A Smart Addition to Any Shop
This jig is proof that you don’t need expensive equipment to achieve professional results. With just a circular saw and a homemade jig, you can handle a wide range of cutting tasks with confidence.
Even seasoned woodworkers will find it useful for quick breakdowns or when portability matters. It’s lightweight, easy to build, and a great alternative when setting up a table saw isn’t practical.
Learn by Building
Rob’s project is as much about learning as it is about the final product. Building the jig helps reinforce key woodworking principles—like alignment, measurement, and safe cutting techniques.
It’s a small but powerful reminder that good woodworking doesn’t rely on high-end tools. With a little effort and some thoughtful planning, simple builds like this can have a big impact on your shop workflow.
Get Rob’s plans here: https://makethingswithrob.com/circular-saw-cut-off-jig/.