Upgrade Your Woodworking: Precision Table Saw Fence

Table of Contents

1. Introduction
2. Inspiration from Jer Schmidt
3. Materials and Tools Needed
4. Building the Runner
5. Welding the Strip Plate
6. Creating the Threaded Rod Holder
7. Attaching the Handle Bracket
8. Joining the Aluminum Extrude
9. Assembling the Rail Slider Mechanism
10. Adding the Thrust Bearing
11. Attaching the Bracket to the Table Saw Cabinet
12. Adding the Slider Rail
13. Calibrating the Distance
14. Assembling the Locking Mechanism and Handle
15. Final Assembly and Calibration
16. Calibrating the Fence
17. Making the First Cut
18. Applying the Patch Meter
19. Using the Micro Adjuster
20. Setting up for Repeatable Cuts
21. Conclusion

Building a Table Saw Fence with Micro Adjuster

Are You looking to enhance the functionality of your table saw? Why not build a table saw fence with a micro adjuster? In this article, we will guide you through the step-by-step process of building this useful tool, inspired by Jer Schmidt's design. We will cover all the materials and tools needed, provide detailed instructions for each stage of the build, and offer tips for calibrating and using the fence effectively.

1. Introduction

Before we dive into the details, let's discuss the importance of a table saw fence. A table saw fence is a vital component that helps in achieving accurate and straight cuts. It acts as a guide for the workpiece, ensuring precise alignment and reducing the chances of kickback. While most table saws come with a stock fence, building a custom fence with a micro adjuster can significantly improve the precision and versatility of your woodworking projects.

2. Inspiration from Jer Schmidt

Our design is inspired by Jer Schmidt, a renowned woodworking enthusiast and content creator. We highly recommend checking out his YouTube Channel for more woodworking tips and inspiration.

3. Materials and Tools Needed

Before starting the project, Gather all the necessary materials and tools. Here's a list of what you'll need:

Materials:

• Angle iron (4 cm X 4 cm X 30 cm)
• Strip plate (30 cm X 3 cm X 2 mm)
• 4 cm by X 6 cm square tube (40 cm length)
• 4 cm by 4 cm square tube (3 mm thickness)
• M20 threaded rod with 4 m20 nuts
• Steel plate (4 cm X 10 cm X 5 mm)
• Strip plate (2 mm thickness)
• Bearings (6204)
• 20 mm shaft

Tools:

• Drill
• M6 tap
• Welding equipment
• Jig for creating a 20 mm groove
• Table saw
• Epoxy adhesive
• 8 mm stainless pipe
• Caliper for measurements

4. Building the Runner

The runner is an essential part of the fence, providing smooth sliding motion. Follow these steps to build the runner:

1. Cut the angle iron to a length of 30 cm.
2. Drill four holes in the angle iron and tap them with the M6 tap.
3. Attach the strip plate to the angle iron using welding. Ensure the strip plate has a hole in the center for welding.

Pros:

• Sturdy and Durable
• Budget-friendly

Cons:

• Requires welding skills

5. Welding the Strip Plate

The strip plate plays a crucial role in joining the angle iron and the runner. Follow these steps to weld the strip plate to the angle iron:

1. Weld the strip plate to the angle iron through the pre-drilled hole.
2. Use epoxy rapid cure epoxy to attach a thin strip of nylon or HDPE to the strip plate, ensuring smooth and silent sliding.

6. Creating the Threaded Rod Holder

The threaded rod holder holds the threaded rod in place, allowing for easy adjustability. Follow these steps to Create the threaded rod holder:

1. Make a half-circle groove in a 20 mm rod using a jig on the table saw.
2. Insert the threaded rod into the groove of the threaded rod holder.

7. Attaching the Handle Bracket

The handle bracket provides a comfortable grip for adjusting the fence position. Follow these steps to attach the handle bracket:

1. Weld the handle bracket to the 20 mm rod.
2. Use an 8 mm stainless pipe to connect the handle bracket to the fence.
3. Secure the handle bracket using an M6 bolt.

8. Joining the Aluminum Extrude

The aluminum extrude adds stability and precision to the fence. Follow these steps to join the aluminum extrude:

1. Drill holes in the aluminum extrude for the sliding T-nuts.
2. Use welding or adhesive to attach the aluminum extrude to the fence.

9. Assembling the Rail Slider Mechanism

The rail slider mechanism allows the fence to slide in and out smoothly. Follow these steps to assemble the rail slider mechanism:

1. Insert the square tubing into the runner.
2. Attach the rail slider brackets to the square tubing using welding or screws.
3. Ensure the brackets are square with the table saw cabinet for precision.

10. Adding the Thrust Bearing

The thrust bearing ensures smooth movement and stability of the fence. Follow these steps to add the thrust bearing:

1. Weld one section of the thrust bearing to the bracket.
2. Insert the remaining sections of the thrust bearing without tightening them too much.

11. Attaching the Bracket to the Table Saw Cabinet

Securing the fence bracket to the table saw cabinet ensures stability and accuracy. Follow these steps to attach the bracket:

1. Weld or screw the fence bracket to the table saw cabinet.
2. Ensure the bracket is square with the cabinet by checking for alignment.

12. Adding the Slider Rail

The slider rail provides additional support and ease of movement for the fence. Follow these steps to add the slider rail:

1. Attach the slider rail to the bracket using an M6 bolt and secure it with a nut.

13. Calibrating the Distance

Precise calibration of the fence distance is crucial for accurate cuts. Follow these steps to calibrate the distance:

1. Use the bolts on top of the runner to adjust the squareness of the fence with the table top.
2. Adjust the alignment of the fence with the blade.

14. Assembling the Locking Mechanism and Handle

The locking mechanism ensures the fence stays in place during operation. Follow these steps to assemble the locking mechanism and handle:

1. Weld the 20 mm rod to the handle for comfortable gripping.
2. Use an 8 mm stainless pipe and an M6 bolt to connect the handle to the locking mechanism.

15. Final Assembly and Calibration

Assemble all the components together and ensure proper alignment and functionality. Calibrate the fence to achieve optimal performance.

16. Calibrating the Fence

Calibrate the fence to achieve accurate and repeatable cuts. Use the provided bolts to square the fence with the table top.

17. Making the First Cut

Perform a test cut to determine the patch meter's position on the rail slider for precise measurements.

18. Applying the Patch Meter

Apply a patch meter to the rail slider for accurate measurements. Cut a strip with the desired length and attach it securely.

19. Using the Micro Adjuster

Utilize the micro adjuster to make small adjustments to the fence position for fine-tuning your cuts. Enjoy the enhanced precision and ease of use provided by the micro adjuster.

20. Setting up for Repeatable Cuts

Slide out the fence to set up for repeatable cuts without worrying about kickback. The fence's sliding capability allows for precise and safe repetitive cuts.

21. Conclusion

Congratulations! You have successfully built a table saw fence with a micro adjuster. Enjoy the enhanced precision, versatility, and ease of use this custom fence provides. Remember to always prioritize safety when operating the table saw. Happy woodworking!

Highlights

• Build a custom table saw fence with a micro adjuster for enhanced precision and versatility.
• Gather the necessary materials and tools before starting the project.
• Follow step-by-step instructions to build each component of the fence.
• Calibrate the fence and perform test cuts for optimal performance.
• Utilize the micro adjuster for small adjustments and enjoy repeatable cuts with ease.

FAQs

Q: Can I build this table saw fence if I'm a beginner in woodworking? A: While some welding and woodworking skills are required, this project can be completed by beginners with proper guidance and precautions.

Q: How long does it take to build the table saw fence with a micro adjuster? A: The construction time will vary depending on your skills and tools available. It may take a few hours to a full day to complete the project.

Q: Can I customize the Dimensions of the fence to fit my table saw? A: Yes, you can customize the dimensions according to the specifications of your table saw. Ensure proper alignment and squareness during assembly.

Q: What are the benefits of using a micro adjuster on a table saw fence? A: A micro adjuster allows for precise and fine-tuned adjustments, ensuring accurate cuts. It enhances the versatility and ease of use of the table saw.

Q: Is it necessary to have a patch meter for the rail slider? A: While not mandatory, a patch meter provides additional accuracy and convenience for repeatable measurements. It is recommended for precise woodworking projects.