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This guide project can be used with almost any portable cutting tool, such as a circular saw, jigsaw, or router. It's designed to handle two tools - a different one for each side. These instructions are for building one 2.5 metre-long guide, but the materials will yield three lengths. Make shorter guides with leftovers.
You will need:
[1] 1200 x 2500mm of 6mm hardboard
[6] 1200 of 8mm aluminium channel
Flat-slotted machine screws with nuts
Quick-set epoxy
Mineral turps
Here's how:
1. Rip a 400mm-wide strip from the hardboard for each guide you plan to make.
2. To ensure a good bond between [2] aluminium channels and the panel, clean the bottom of the channels and the surface of the panel with turps and sand lightly.
3. Locate and mark the centre of the hardboard panel at both ends. Make marks 6mm to one side of the centre of the panel and snap a chalk line at these marks.
4. Mix the epoxy and apply it to the bottom of the channels.
5. Lay the channels along the chalk line and set a light weight on top. Let the epoxy cure overnight.
6. Locate the centre of the channels on the back of the assembly and snap the line to mark it.
7. Use a countersink pilot bit to drill holes approximately 150mm on centre along this line through the panel and channels. Secure the channels to the panel with flat-slotted machine screws and nuts.
8. To customise the guide select two power tools to use with the guide. Align the base plate of one tool against the channel, and run the tool along the length of the channel, cutting off the un-needed portion. Repeat on the other side of the panel for use with a different tool.
9. Label both sides of the panel with the name of the tool to be used.
10. To use the guide, mark the material where it needs to be cut and place the edge of the panel at that mark. Clamp in place and make the cut. No offset measurements are necessary.
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