Repetitive Panel Cutter Jig
- Useful for both regular and repetitive cuts for panels
- Adjustable Stop Block for repetitive cuts
- Adjustable Stop Block quickly lifts up out of the way
for regular cuts
- Clamp Arm holds work piece securely in place
- Both the Panel Cutter handle and the Door Pull are
easily removable for larger panels
- Adjustable foot on the Clamp Arm is useful for different
size work pieces
- Spring hinge holds the Clamp Arm in place during storage
- Wardrobe Door Rollers [for a Sliding Closet door]
mortised on top of the Panel Cutter make it easy to slide the Panel Cutter in
and out of storage under the table saw.
Adjustable Stop Block & Minitrack details
- The Adjustable Stop Block you make will require custom
measurements because I used scrap metal for a track rather than a Minitrack.
Below are my Adjustable Stop Block measurements to help you design your own
Adjustable Stop Block.
- Track part – 1" x 2" x 5-1/4" [this will ride over
- Gate part – 1" x 3" x 2-1/2"
- Hinge –self closing flush cabinet hinge
- 36" Minitrack –Woodworkers Supply - Item # 115-319. Cut
to convenient length [I used 31-1/2"]
- Bolt & Wing nut [or equivalent] – to tighten Adjustable
Stop Block on the Minitrack.
- Hook lift [or knob] to attach to Stop Block Gate
Clamp Arm details
- Adjustable Clamp foot
- 3/8" elevator bolt. Hint: epoxy a rubber disk to the
bottom of the bolt to prevent marring of work piece
- 1" x 2" mending plate. Drill a 3/8" hole in the
center of the mending plate for the elevator bolt
- 3/8" wing nut
- 3/8" washer
- Screen door self-closing spring hinge to mount to the
- Clamp Arm Mounting Base dimensions
- Top Section - (1) ¼" x 1-3/16" x 3-7/8"
- Bottom Section - (1) ¾" x 1-7/8" x 3-7/8"
- Make a centered 3/16" x 1-1/8" dado cut the length of
the Clamp Arm [see Figure 2]
- Start 3-1/4" from the top of the Clamp Arm and use a ½"
router bit to make a 19" long slot in the center of the dado cut.[see Figure
Panel and Track Base details
- Panel - ¾ plywood – dimensions – 30-1/2" x 30-1/2"
- Cut a 23" x 12" section off the panel where indicated
[see Figure 1]
- Rout out 'hand hold' in a convenient location [see
- Track Base - (1) ¾" x 2-1/4" x 30-1/2"
Misc Material List details
- 32-1/2" - ¼" x ¾" steel flat stock – found at any home
- Drill and countersink holes in ¼" x ¾" steel flat
stock to attach to Panel Cutter and to attach to Panel Cutter handle
- If you have a Craftsman table saw, you may have to
sand the ¼" x ¾" steel flat stock slightly to fit into the table saw miter
- Aluminum yard stick – cut to convenient length [I used
30"] – drill and countersink holes to attach to Track Base.
- Panel Cutter handle – (1) ¾" x 4" Dowel drilled to hold
bolt and wing nut.
- 4-7/8" 2 hole Door Pull to mount to the Panel Cutter
[this gives you leverage when using the Clamp Arm]
Assembly instructions: Read before assembly
- Square and mount the ¼" x ¾" steel flat stock to the
bottom of the Panel Cutter using only 2 screws (in case you have to make any
adjustments). Make sure that approximately ½" of the panel will be sawed off
when the Panel Cutter is run through the table saw for the first time.
- Square and mount the Track Base to the Panel Cutter
using only 2 screws (in case you have to make any adjustments). Make sure
that approximately ½" of the Track Base will be taken off when the Panel
Cutter is run through the table saw for the first time.
- Slowly push the oversized Panel Cutter with the
oversized Track Base attached through the table saw.
- Next push the Panel Cutter through the table saw with a
test work piece and check for square. This step is essential. Recalibrate the
Panel Cutter if necessary.
- Install the remaining screws on the ¾ steel flat
stock and the Track Base.
- Mount the Top and Bottom sections of the Clamp Arm
Mounting Base on the Track Base.[see Figure 1 for exactly how and where to
- Indent 1" and mount the Clamp Arm with the Screen door
self-closing spring hinge.
- Design your Adjustable Stop Block before you mount the
- Attach the remaining items: Aluminum yard stick,
Minitrack and Adjustable Stop Block, Door Pull, and Panel Cutter handle.
How to Use
- Place Panel Cutter on the table saw. Position it just
behind the saw blade.
- For repetitive cuts, set Adjustable Stop Block at
- For regular cuts, lift Adjustable Stop Block out of the
- Adjust Clamp Arm foot, if necessary
- If necessary, grasp Door Pull with 4 fingers and depress
the Clamp Arm with your thumb with your right hand and make the cut [see
Figure 3 for hand position].
- For extra large panels, you may have to remove the Door
Pull and the Panel Cutter handle
- You have your choice of using your right hand to grasp
either the Panel Cutter handle or the Door Pull.
Figure SEQ Figure \* ARABIC 1 Repetitive Panel Cutter
Figure SEQ Figure \* ARABIC 2 Clamp arm Details
Figure SEQ Figure \* ARABIC 3 How to Use [Hand position]
Figure SEQ Figure \* ARABIC 4 Adjustable Stop Block