The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

Chapter 12 – Scarfing 113
Figure 12-8 A plywood panel with a bevel cut using the
Scarffer attachment.
Building a production jig for cutting plywood scarfs
You can also build a jig for cutting plywood scarfs with
a circular saw, as shown in Figure 12-9. This jig can be
set over an existing table or made freestanding. <strong>The</strong> jig
Table Saw Track (section)
Blade guard
Adjust track
width to match
saw base
Circular Saw Method
Plywood bevel
Cutting table
Figure 12-9 A jig for cutting plywood scarfs.
Clamping bar
Closed cell
foam strip
Blocking
Extend 2 x 4 beyond table
edge for clamping
8:1 Angle
Table
Spacer
fence
Metal edge
Clamping bar
Saw track
Metal straight edge
lets you cut an accurate bevel on the end of a plywood
panel and doesn’t tie up your circular saw with a semipermanent
attachment like the Scarffer.
A standard circular saw is guided by a track mounted
on the end of the table, below the table’s edge. You can
make the guide of 3 ⁄4" (18mm) plywood. Mount it at the
appropriate angle to form an 8-to-1 bevel with relation
to the table top when the saw is set for a normal 90°
cut. <strong>The</strong> plywood forms a flat plane that the base of the
circular saw can follow. A permanently mounted
straightedge strip holds the saw at the appropriate
height and guides it along the length of the cut. Set this
tool up with a clamping bar to hold the plywood flat
against the table. <strong>The</strong> clamping bar should include a
feature that will protect the operator from the exposed
saw blade while the scarf is being cut. <strong>The</strong> advantage of
this jig is that it lets you use a circular saw without
modifications. Nothing is attached to it, and the
retractable blade guard is left to operate freely.
Making bevels by hand
A prime requirement for hand beveling is a flat table
or bench of sufficient size and with an edge that will
support the plywood edge you are beveling. Position
Table Fence (section)
1/4" Gap allows sawdust
to fall through
Blocking 12" – 16" O.C.