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Panel Saw Plans

This Panel Saw can be stored away in a corner of your shop when not in use and quickly set up
on two saw horses when needed. It features:
• Four independent Tracks that clamp to two 2x4s.
• Twelve risers that keep the workpiece elevated ¾” above the tracks for saw blade clearance.
• Four Panel Clamps that clamp the workpiece in position. Each Panel Clamp has a ¾” base
that supports the workpiece at the same height as the risers.

The risers are positioned so both sides of the workpiece are supported after the cut is made.
• If your cut will be along the length of the workpiece, position the Tracks so they are equally
spaced (the exact spacing is not critical). Then, position the risers so the workpiece will be
supported near the cut but the risers are not in the path of the blade.
• If your cut will be across the workpiece, position the two inner Tracks so one is on either side
of the cut. Be sure the risers are not in the path of the cut.

After the Tracks and risers are properly positioned:

• Clamp the Zero Clearance Guide to the workpiece for your saw to follow.
• Set your saw blade height so the blade cuts completely through the workpiece but does not
touch the Tracks.

When finished, simply dismantle the setup and store the components until next time they are
needed.

Copyright © 2005 by Robert E. Reedy

All rights reserved
 Saw Horse Panel Saw Plans

Table of Contents

Materials List .................................................................................................... 1

Panel Clamp Parts Drawings ............................................................................ 2
Panel Clamp Assembly ..................................................................................... 3
Panel Risers ....................................................................................................... 4
Rail Clamps ....................................................................................................... 5
Panel Saw Tracks .............................................................................................. 6
Clamp Usage ..................................................................................................... 7
Rail & Track Setup ........................................................................................... 8
Riser & Panel Clamp Placement ....................................................................... 9
Zero Clearance Guide Parts Drawings ............................................................ 10
Zero Clearance Guide Assembly .................................................................... 11
Panel Saw Usage ............................................................................................. 12
Cut-out Diagrams ............................................................................................ 13
Hardware Sources & Links ............................................................................. 14
 Saw Horse Panel Saw Materials List
Page 1

Qty Item Length Width Thickness Material

4 Track Base 54” 2 ¼” ¾” Hardwood or Pine
8 Track Sides 54” ¾” ¾” Hardwood or Pine
4 Panel Clamp Jaw 4” 2” ¾” Hardwood or Pine
4 Panel Clamp Base 4” 2” ¾” Hardwood or Pine
4 Upper Clamp Pad 2” ¾” 1/8” Hardwood or Pine
4 Lower Clamp Pad 2” 1 ½” ¼” Hardwood or Pine
12 Panel Riser 6” 2 ¼” ¾” Hardwood or Pine
12 Panel Riser Slide 6” ¾” 5/8” Hardwood or Pine
12 Dowel Pin 1 ¼” 5/16” Dowel Pin
4 Rail Clamp Jaw 4” 2” ¾” Hardwood or Pine
4 Rail Clamp Pivot 2” 1 ½” ¾” Hardwood or Pine
2 Rails 6’ 3 ½” 1 ½” Two by Four (Pine)
1 Zero Clearance Base 96” *10” ½” or ¾” MDF Board

1 Saw Guide 96” 3” ½” or ¾” MDF Board

* This dimension is determined as per the instructions on page 10.

Hardware
QTY Item Size
4 Levelers Height: 1 ½”, Width: 1”, Threads: 5/6” - 18 TPI
4 T-Nuts Threads: 5/6” - 18 TPI
12 Carriage Bolts Length: 4 ½”, Threads: 5/6” - 18 TPI
12 Star Knobs or T-Knobs Width: 2”, Threads: 5/6” - 18 TPI
12 Flat Washers 5/16”
32 Flathead Wood Screws Length: 1 ¼”, Size: #6

Copyright © 2007 by Robert E. Reedy

All rights reserved
 Panel Clamp Parts Drawings
Page 2

4"
1"
3/4" 5/8"
2 1/4"

d)
uire
eq
( 4R D 5/16" D 5/16"
aw
mpJ
l a
lC
2"
ane
P
Panel Clamp Jaw (Hole Layout)

Drill the 5/16" diameter holes in the Panel Clamp Jaws according to the layout drawing above.
Both holes are drilled completely through the workpiece.

4" 1/2" 1"

1 3/4"

)
ed
uir
Req D 5/16"
4
e(
B as
l amp
l C
2" ne
Pa Panel Clamp Base (Hole Layout)

Drill a 5/16" diameter hole completely through

each Panel Clamp Base as shown above.
1 1/2" 2"
3/4"
2"
1/4"

1/8" Thick

Lower Pad (4 required) Upper Pad (4 required)

You'll need four upper pads and four lower pads. No need to drill holes in
these. They are attached with glue and small brads.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Panel Clamps Assembly
Page 3

1 3/4"

Attach the Upper Pads to the Panel Clamp Jaws
with glue and small brads.
Next, tap the T-Nuts into the 5/16" hole and
insert the levelers as shown.
Attach the Lower Pads to the Panel Clamp Bases
with glue and small brads. Note: Since the 5/16"
hole is not centered in the Panel Clamp Base, be
sure to position the pad so the hole is 1 3/4"
from the end as shown.

Panel Clamp Jaw

The Panel Clamps are assembled as shown to the T-Nut Upper Clamp Pad
Leveler
right. The levelers are necessary so you can use Clamp Base
Lower Clamp Pad
Panel Clamp Base
the clamps with different thicknesses of panels.
Track

This drawing shows the Panel Clamp is use.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Panel Risers
Page 4

2 1/4"
D7/64"
3/4"
6"

1" 1 1/8" 1"

d ) Panel Riser (Bottom View)

ire
qu
2 Re Drill a 7/64" pilot hole 1/2" deep and 1 " from
e r (1 each end and centered side to side for #6 wood
Ris screws.
el
P an Cut a 3/4" wide by 1/8" deep
dado from end to end for the
guide.

3 1/2" 3/8"

D5/16"
1" 1"

Panel Riser Guide(Top View)

5/16" by 1 1/4" Dowel Pin 3/4"
(12 Required) Drill and countersink a hole 1 " from each end
and centered side to side for #6 wood screws.
Countersink should be 5/16" diameter and shank
hole size 9/64".
5/8"
6"
Next, drill a 5/16" hole 3 1/2" from one end for
)
ed the 5/16" dowel pin. This hole should be 1/2"
uir
R eq deep. Placing the hole in this position allows a
e ( 12 change of one inch from the end of the riser
id from the holes in the track by turning the riser
r Gu
e end for end.
l Ris
ne
Pa

Apply glue to the mating surfaces and secure the Panel

Riser Guides to the Panel Risers as shown to the right.

Apply glue to 1/2 the length of the 3/8" dowel pin and
insert it through the center hole as shown.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Rail Clamps
Page 5

4"
1"
3/4" 2 1/4"

d)
ire D5/16"
qu
4 Re
w(
p Ja
Clam
2" i l Rail Clamp Jaw (4 Required)
Ra

Drill a 5/16" diameter hole in the Rail Clamp Jaws according to the layout drawing above. Holes
are drilled completely through the workpieces.

2"

1 1/2"

3/4"
Assemble the Rail Clamps
with glue and finishing nails
Rail Clamp Pivot (4 required)
as shown.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Panel Saw Tracks
Page 6

2 1/4"

)
54" ed
quir
e
( 4R
e
as
c kB 2".
Tra ever
y
eat
rep
d and
en
the
om
2" fr 3/4"
at
g
rtin
s ta
ra cks
3/4"
ne lT
Pa
the
r of
ce nte
t he
ng
s alo )
e ed
" hol 54" quir
3/ 8 e
2" ill ( 8R
Dr s
uide
e G
S id

3/4"

Apply glue to the mating surfaces and attach the Side Strips to the
Track Base with finishing nails as shown above. Remember, the
Panel Risers must slide in the Track so be sure the space between
is 3/4" wide. You may want to place spacers between the Side
Strips wihile attaching them to ensure the space is correct.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Clamp Usage
Page 7

Panel Clamp
Workpiece
Riser

Rail

Track

Rail Clamp

The drawing above illustrates clamping the workpiece (panel) to the tracks and
clamping the tracks to the rails. The levelers on the Panel Clamps can be adjusted for
panels of varying thickness.

The purpose of the risers is to raise the panel above the tracks so the saw blade does
not come into contact with the tracks. The risers provide 3/4" clearance between the
bottom of the panel and the tracks. Be sure your blade does not protrude far below the
workpiece to damage the Tracks.

The panel needs to be supported on both sides of the saw kerf so the pieces don't drop
after the cut is made. For this reason, you should place the risers so they are as close
to the kerf as possible and the kerf is between risers.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Rail & Track Setup
Page 8

24"

Place Two 2 by 4s on your saw horses so they

are 24" apart.

Place the tracks as shown below. If you are sawing along the
length of the panel, the spacing is not critical.
If you are sawing across the panel, space the
tracks so they don't interfere with the saw kerf.
You will need to have two tracks under each
section of the panels after the cut so the panels
are properly supported.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Riser & Panel Clamp Placement
Page 9

Place the Risers and Clamps so the workpiece will be supported on both sides
of the cut. The dowel pins on the bottom of each Riser keep the Risers in
position when the workpiece in resting on them.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Zero Clearence Guide Parts Drawings
Page 10

3"

1/2" or 3/4" Thick MDF Board

Sa
wG
uid 96"
e

Ze
ro
C le
ara
nc 96"
1/2" or 3/4" Thick MDF Board eB
as
e(
2R
eq
u ir e
d)

Electric
Hand Saw

Edge
5 1/2"

Saw Blade

To determine the width of the Zero Clearance Base, add 3 1/2" to the
distance from your saw's blade to the edge of the saw's base as shown
above.

Example: If the saw blade to edge distance is 5 1/2", add 3 1/2" to this
measurement to determine the width of the Zero Clearance Base. In this
case it would be 9".

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Zero Clearence Guide Assembly
Page 11

Apply glue to the mating surfaces and attach the Saw Guide to the Zero
Clearance Base with 1 1/4" # 6 wood screws as shown.

After the glue has dried, set your saw up as shown above and trim the left
edge of the Zero Clearance Base by running the saw along the Saw
Guide. This will make the Zero Clearance Base exactly the right width to
provide a splinter free cut.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 Panel Saw Usage
Page 12

Sacrificial Board

6 1/2"

To use your Panel Saw, first, draw a line on the workpiece for the cut. Then, align the left edge of
the Zero Clearance Guide to the cut mark and clamp the guide in place with a couple of C-Clamps.
The clamps will need to be placed over the thickest part of the Saw Guide so they do not interfere
with the saw travel.

The Zero Clearance Guide will provide a splinter free cut on the right side of the kerf because it
holds the fibers down and keeps them from splintering. To have a splinter free cut on the left side
of the kerf, place a piece of 1/2" thick material against the Zero Clearance Guide and clamp it in
place with C-Clamps. This "sacrificial board" will hold the fibers down along the left side of the
kerf while the cut is made.

If you find it awkward to use the 96" Zero Clearance Guide for cutting across the width of panels,
you may want to make a 48" long one for that purpose.

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio

 These cut-out drawings show how to cut the majority of the parts from five 6" by 72'
boards. The smaller parts that aren't pictured can easily be cut from the left overs.

The Zero Clearance Guide should be made of material that is not prone to warping. For
this reason, I used MDF board for the prototype.

72"

Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12) Panel Riser (12)

Copyright
Clamp Jaw Clamp Jaw Clamp Jaw Clamp Jaw

5 1/2"
Panel Riser (12) Clamp Base Clamp Base Clamp Base Clamp Base Rail Jaw Rail Jaw Rail Jaw Rail Jaw

Track Base (4)

Track Slide (8)

5 1/2"
Track Slide (8)
Page 13

Track Slide (8)

Cut-out Drawings

Track Base (4)

Track Slide (8)

5 1/2"
Track Slide (8)
Track Slide (8)

2007 by Robert E. Reedy, Vandalia, Ohio

Track Base (4)

Track Slide (8)

5 1/2"
Track Slide (8)

5 1/2"
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