How to Build a Homemade Track Saw

Track saws are useful tools for any DIY enthusiast. They help you make precise, straight cuts in large plywood sheets or other materials while staying safe. Pre-made track saws come with a hefty price tag, but you can make your own at a fraction of the cost.

In this guide and video, we’ll explain how to build a homemade tack saw and the benefits of having one ready to go every time you need it.

Why Make a Track Saw?

A track saw consists of a circular saw that slides along a metal track or rail, which helps guide the saw for accurate and smooth cuts. That makes it especially useful for long cuts, such as cutting large sheets of plywood, and the saw can be adjusted for depth and angle to create bevels or plunge cuts.

These tools have several advantages over traditional circular saws, which include:

• Ability to make long, straight cuts in large sheets of material
• Cleaner cuts with minimal splintering
• Improved accuracy and precision
• Increased safety due to the guided cutting path
• Reduced need for measuring and marking

Your DIY track saw won’t be as fancy as the professional-grade ones you can buy, but you will still be able to reap many of the benefits.

Tools You’ll Need

You need to collect several items before you begin to build your track saw. They include:

• Circular saw
• Clamps
• Measuring tape or ruler
• Pencil
• Sandpaper (optional)
• Scrap plywood (at least 1/4 inch thick)
• Wood glue

Building Your Homemade Track Saw

This is a simple DIY project that will take you no more than 10 minutes. Follow the steps below:

1. Cut a thin strip of plywood: Grab your circular saw and cut a thin strip of plywood. Make sure that it’s slightly wider than the base plate of your circular saw.
2. Prepare the base: Next you’ll need a piece of plywood that’s longer and wider than the one you cut in the first step. Take another plywood scrap and line it up against the other to make sure it’s the right size and cut it as needed.
3. Apply wood glue: Put a thin, even layer of wood glue on one side of the thin plywood strip.
4. Attach the strip to the base: Place the glued side of that strip along the edge of the wider piece and push down firmly to make sure it sticks together. Leave excess plywood on both sides of the glue joint.
5. Allow the glue to dry: Your wood glue’s manufacturer’s instructions will tell you how long it takes for it to dry. Follow those guidelines by leaving the track undisturbed for that length of time. 
6. Trim the excess: After the glue is dry, place your circular saw against the raised edge of the track and cut off the excess plywood.
7. Flip and repeat: Turn it over and repeat the process on the other side. Make sure you align the edges with your saw’s blade for a straight cut.
8. Sand edges: You can sand the track so you don’t get a splinter or encounter any rough spots, but this step is optional.  

Using Your Homemade Track Saw

Now that you’ve built your track saw, it’s time to put it to use. Here’s how to make accurate cuts with your new tool:

1. Mark your cutting line: Use a pencil to mark the desired cutting line on your workpiece.
2. Position the track: Align the edge of your homemade track with the marked cutting line. The edge of the track should correspond to where the saw blade will cut.
3. Secure the track: If necessary, use clamps to hold the track firmly in place on your workpiece.
4. Make the cut: Place your circular saw on the track, ensuring the saw’s base plate is flush against the raised edge. Turn on the saw and guide it along the track to make your cut.

You can ensure that you get the most out of your homemade track saw by cleaning and sharpening the blade of your circular saw before you use it. You’ll also want to store the track in a dry place so humidity doesn’t warp the wood. 

Limitations of a Homemade Track Saw

A DIY track saw is certainly cheaper, but there are a few limitations. While they aren’t meant to deter you from creating your own, keep these in mind when you use it: 

• Less precise than professional models: A homemade version won’t have exact accuracy that commercial track saws do.
• Limited features: Unlike some professional-grade models, a homemade track saw doesn’t have dust collection or plunge-cutting capabilities.
• Fewer safety features: Store-bought track saws come with built-in safety features like anti-kickback mechanisms, dust collection ports, and blade guards, which may be difficult or impossible to replicate in a homemade version.
• Less portability: Professional track saw systems are often designed to be portable and easy to set up, with lightweight tracks and carrying cases. Homemade versions may be bulkier and harder to transport.

Enhancing Your Homemade Track Saw

For those looking to take their homemade track saw to the next level, several enhancements can be added to improve functionality and ease of use.

• Adjustable guide rails: You can add sliding mechanisms to the track’s sides and adjust the guide rails widths to fit different saw blade sizes. 
• Non-slip strips: Adding a non-slip membrane on your track’s bottom will help stabilize your track and reduce the need for clamps. You can purchase adhesive non-slip strips or repurpose materials such as old rubber mats.
• Dust collection system: Attach a vacuum hose near the saw blade to collect sawdust as you cut, which will help you keep things cleaner.

Our Conclusion

Making a homemade track saw is a solution for DIY enthusiasts and woodworkers looking to improve their cutting accuracy without having to break the bank. We recommend you take the proper safety precautions, such as wearing protective gear while using a circular saw, keeping your hands away from the blade at all times, and using clamps to secure your workpiece. You can also regularly inspect your track for signs of wear and damage so that you can repair as needed.