How to Make a Table Saw Fence

What You'll Need
Design plans
Welding materials
Aluminum rails
Metal cutting band saw
Drill press
Thread cutting taps
Bench grinder

There are many styles of table saw fences available. You can purchase a pre-made saw fence, or save some money and build your own. Since there are so many variations with table saw fences, this article will cover a basic T-square fence. A T-square fence is one of the most common table saw fence used. 

Step 1 - Design a Plan

The plan design is the most important aspect when building anything. A table saw fence is no exception. Draw out what you are wanting to achieve, and then scale it once you have a design idea. Scaling it will require accurate measurements. You will need to measure the dimensions of the table you are working on, as well as have an idea of what the fence will be used for on future projects.

Step 2 - Start with Supports

To make a support for the third miter gauge slot, bolt a 1 3/4 by 1 3/4 inch angle to the side of a table, 3/8 inches below the table top.

Step 3 - Work on Back Piece

Using the same length measurements, bolt another length along the back of the table, below the miter slots. Bolt a 3/4 by 3/4 inch piece of angle iron to the inside to support the router table. To determine the position, clamp a piece of angle iron across the table top, then place the already made router table panel in between the support and it. Clamp in position and drill 1/4 inch bolt holes.

Step 4 - Mount the Rail

To mount the rail to the table front, drill 5/16 inch holes. To support the router table, drill 1/4 inch holes to secure a length of 3/4 by 3/4 inch angle. The 5/16 inch and 1/4 inch holes must be countersunk and, for mounting, must use flat head bolts.

Step 5 - Start the T-Square

Cut a piece of tube and drill a hole large enough for an 8-32 screw. This is where you will end up fastening a glider. Drill 3 more 1/4 inch holes through the side, making sure there is one at each end and one on the center. 

Step 6 - Welding

This is where the welding experience and materials are needed. You will need to weld the T-square together and place any of the glides that you are using. You can use your left over materials to create a lock, or you can purchase a pneumatic clamp to secure the fence in place. A fence that hasn't been secured will do you no good during your project creation, and can be dangerous. Pneumatic clamps are the best route to go, they aren't expensive and are very reliable.

A table saw fence can be useful in many applications. They help to guide the lumber, creating even cuts. They allow you to move more freely without compromising the cuts you are making. Fences can be created specifically for certain projects. Most hardware and home improvement stores will sell pre-made fences, and will also have the plans available if you wish to create your own.