Simple dowel Cutter
A few years ago, I made this bandsaw sled. I still use it today, but I decided to make a stripped down simpler version just for cutting dowels. Dowels are a tricky material to cut as they can go airborne or even seriously damage bandsaw blades, not to mention make us jump, which puts us in a dangerous situation.
It’s for this reason that I made the following jig that I think anyone with a bandsaw can make. It uses a grippy surface that keeps the dowel from spinning precariously out of our fingers. This jig, besides using a hand saw, is, in my opinion, the safest way to cut dowels.
watch all steps in this video before starting
Please use the material and tool list below as a guide to finding the products locally.
Materials
- (3) 3/4″ x 3/4″ 3 1/4″ soft/hard wood
- 3/4″ x 1 1/2″ x 5″ soft/hard wood
- 3/4″ x 2 1/4″ x 5″ soft/hard wood
- 1/2″ x 3 1/4″ x 5″ plywood
- Tracker Runner (see this before continuing)
- Wood glue, Mod Podge, super glue
Tools Needed/used
- Bandsaw
- Speed square
- Fine ruler
- Pencil
- Glue mat
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Step by step instructions
1. Adding Carpet Runner
We’ll add a bit of tracker runner to the smaller of our two sled top pieces. With either a 50/50 solution of white glue or Mod Podge, we’ll add it to the surface and clamp it.
Click image to see this step on youtube
2. Gluing the sled
After we’ve sanded the edge of the tracker runner piece, we’ll glue it to the larger of the two sled top pieces. I used tape…but honestly, I don’t think it’s necessary. Use a couple f-clamps and give it a few hours to dry.
Click image to see this step on youtube
3. Cutting the supports
We’ll add 3 supports for the base. These will keep the ‘v’ shape for the block. First measure over and then use a speed square to mark a 45˚ angle. Finally, we’ll cut it on the bandsaw.
Click image to see this step on youtube
4. attaching the supports
Honestly, you can use a number of methods to attach the supports to the plywood piece. You could glue it and use a pneumatic nailer, screw it from underneath or glue and clamp each of the blocks on. I chose to use super glue and wood glue.
Click image to see this step on youtube
5. Adding the sled top
When the last step has dried, we’ll add glue and then the sled top inside the channel we cut out. You shouldn’t need to clamp it…just add the glue, slide the sled a little bit in the glue and allow it to sit and dry.
Click image to see this step on youtube
6. Operation
Operation is simple at this point. We’ll face the carpet runner towards us, press down on the dowel and into the rubber and make our cut. We’ll obviously not want to cut into the jig so give yourself a little bit of space. It’s crucial that you’re careful with the length of your cut. You obviously couldn’t cut a 1 inch long dowel with this without taking a dangerous chance.
It also works good to find the center of a square dowel. You’ll put the board on the sled so that the stock looks like a diamond and press the square dowel into the blade, flipping to complete.
Click image to see this step on youtube
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