what to use for a table saw rail

What to Use for a Table Saw Rail: Materials, Installation, and Features

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When choosing materials for table saw rails, it’s crucial to consider durability, ease of installation, and compatibility with your specific table saw model. The most recommended options include rectangular tubing, angle iron, and aluminum extrusions. These materials offer the necessary strength and stability for precise cuts. Proper installation and adjustability features are also key factors in creating an effective table saw rail system.

What Are the Best Materials for Table Saw Rails?

The choice of materials for table saw rails can significantly impact the performance and longevity of your setup. Here are the top recommendations:

  1. Rectangular Tubing and Angle Iron
  2. Ideal for custom guide rails
  3. Recommended sizes:
    • Rectangular tubing: 3″ x 2″ 11 gauge
    • Angle iron: 3″x3″x1/4″

  4. Provides excellent stability and easy attachment

  5. Aluminum Extrusions

  6. Precision-machined for accuracy
  7. Available in 42″ or 48″ lengths

  8. Suitable for most table saws

  9. Baltic Birch Plywood

  10. Excellent for the fence itself

  11. Can be laminated for added stability

  12. Formica or Other Laminates

  13. Used for skinning the fence

  14. Offers durability and easy cleaning

  15. UHMW, Teflon, or Delrin

  16. Ideal for facing the rip fence
  17. Slippery and hard-wearing properties
  18. Prevents blade dulling and reduces sticking

What Is the Ideal Length for Table Saw Rails?

what to use for a table saw rail

The ideal length of table saw rails depends on your specific saw and needs:

  • Rectangular Tubing: 6-12 inches longer than the angle iron
  • Aluminum Extrusions:
  • 42″ length for most table saws
  • 48″ length for larger industrial models

How to Install Table Saw Rails?

Follow these steps for proper installation:

  1. Prepare Materials
  2. Cut angle iron and rectangular tubing to size

  3. Use jigsaw or bandsaw if necessary

  4. Attach Tubing to Angle Iron

  5. Drill holes in the bottom of angle iron and tubing

  6. Use 1/4″-20, grade 8, cap head screws with washers

  7. Attach Angle Iron to Table Saw

  8. Drill and countersink holes in angle iron

  9. Use 5/16″ countersunk, grade 8, 1.1/4″ long flat head Allen key bolts

  10. Ensure Proper Spacing

  11. Maintain 20mm (3/4 inch) gap for parallel spacing

  12. Finish and Protect

  13. Apply high-quality primer and paint
  14. Consider professional powder coating

Required Tools:

  • Drill press (recommended)
  • Jigsaw or bandsaw
  • Drill bits and countersink bits
  • Allen key bolts and screws
  • Washers and lock washers
  • Primer and paint or powder coating

What Features Should Adjustable Table Saw Rails Have?

Adjustable table saw rails should include:

  1. Precise Measurements
  2. Guide rail tubing: 50-80mm (2-3.15 inches) horizontally, 50mm (2 inches) vertically

  3. 21mm (13/16 inch) step down from table top to installed tubing top

  4. Adjustability Range

  5. Adaptable to different table saw models

  6. Accommodates various cutting setups

  7. Secure Attachment

  8. Use of tee-nuts and bolts for easy adjustment and stability

  9. Additional Features

  10. T-tracks and miter tracks for attachments and jigs
  11. Durable materials like aluminum extrusions and Baltic birch plywood

By considering these factors and following proper installation procedures, you can create an effective and long-lasting table saw rail system that enhances your woodworking precision and efficiency.

References:
1. https://vsctools.com/faq/
2. https://mwawoodworks.com/the-ultimate-table-saw-fence/
3. https://www.lumberjocks.com/threads/best-table-saw-fence-material.311901/

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