Noah B Woodworks

My brother asked me in January of this year to make him a huge 5.1 sound system. I am not really sure why I agreed to it, because the project was a little outside of my scope. The biggest sections of the project have been done, but there are some things still left to be done. I still need to make a center speaker, and the two surrounds. I’ve made the front left/right and the sub so far. These were particularly challenging for me because the joinery called for huge miters. I don’t have a proper table saw, so ripping miters has been a huge challenge for me.

I’m thinking I’ll do these miters with a jig. I’ve got a bunch of aluminum linear rails from when I took my router table apart. I could use the linear rails in such a way that makes cutting miters relatively easy. My vision for this is a flat surface, with the rails elevated 3/4″-1″ off of the surface. The piece that is being mitered slides underneath the rails. A circular saw is fastened to a plate that is fastened to the rails. I measure and glue a stopping block, so all I have to do is butt the workpiece up against the stopper, run the circ saw down the linear rails and just like that: fairly accurate and quick miters.

Clamping could be as straight forward as holding it down with one hand, but I think I’d like to have some sort of extra hold down. I have a bunch of lever action hold down clamps, but I could figure out another method for the farthest ends of the board to keep everything nice and flat against the jig. I’ve been thinking to make something like this for a very long time, for as long as miters have been an issue. I’ve got 12 big miters that need to be cut accurately, and having something like this should make creating a mitered box easier in the future if I ever needed to do it again.