Replies

1. 
   roc | Nov 27, 2008 11:35am | #1

   There are some simple extruded rails about five inches wide they come with cheep C-clamps and a black steel connector to join two four foot lengths of extrusion.

   I think I bought these at Home Depot. I went to the on line site but found nothing like this. I bought them five years ago or more. They are cheep enough you don't feel bad cutting one to customize it to make a jig etc. Can join more than two.

   Be sure to wax the black connector or they are difficult to pull apart.

   To locate the straight edge take some masonite, put it against the edge and cut into it with your circular saw with the blade you intend to use. Then use this as a set up gauge. Put the saw kerf on your pencil line and put the straight edge against the gauge then clamp the straight edge.

   Another option that is quicker to set up but more frail to carry around:

   Put a straight length of plywood or other stable stock on top of a foot wide length of masonite using glue to hold them together. When the glue is dry run your saw along the straight stock and it will trim the masonite parallel to the straight stock and at the distance the blade on your saw is from the edge of the shoe. Then when you use this straight edge just put the edge of the masonite on your pencil line, clamp and saw.

   Obviously could make longer by using long stock and glue second length of masonite butted against first. In theory the tempered masonite is a little more moisture resistant if on top of your van.

   See this article:

   http://www.taunton.com/finewoodworking/ToolGuide/ToolGuidePDF.aspx?id=2659

   hope this helps
   roc

   
   

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   Edited 11/27/2008 3:48 am by roc

1. 
   habilis | Nov 27, 2008 01:49pm | #2

   Thanks! I new there was something homemade, cheap and solid rattling around the back of my brain. Most of the time 8' is plenty and I can use it in my shop. And It'll fit easily in my van. Have it done before turkey if my wife doesn't have too much cooking and errands for me.

1. 
   heartwould | Nov 28, 2008 05:31pm | #3

   A tip I believe I saw on This Old House was to use the plywood/masonite (or similar materials) combination that has been described, but to cut one side with the cs blade to the "wide" width and the other to the "narrow."  This way you have a dead on straight edge regardless of which way you are cutting. 

1. 
   davcefai | Nov 28, 2008 08:26pm | #4

   I recently bought a length (21 feet) of 40 x 20 mm box section aluminium. This is to give me straight edges for cutting 8',4' and some left over.As far as I could tell it is straight to <1mm in 3 metres. I was told by an engineer that these extrusions are usually very straight so then it's a matter of buying from somebody who stores them well.In point of fact, since these extrusions are used to make partitions and doors they have to be straight - you can't plane an aluminiun door down to fit!

1. 
   larinUP | Nov 29, 2008 01:01am | #5

   Gee, thanks for sharing the "put the wax on" tip - I didn't - guess what?!!! That straight edge is made by Empire. I got mine a few years ago at Menard's. Larry

2. 
   paulbny | Mar 12, 2009 05:43am | #6

   Habilis,

   I have an EZ-Smart, it's a great system.  Check out their website Eurekazone.com  There are A LOT of options that can be added to the system.

1. 
   habilis | Mar 12, 2009 05:56am | #7

   Got a $20 guide made by Johnson. Use it with my clamps, does what I want.
   Can get very nice cuts easily. If I need better,I make the final cut on the table saw dealing with a size I can handle by myself. Thanks.