Circular saw track – quick upgrade

One of the great things about shop projects is coming up with an improvement to an existing idea!

I previously made a track for my circular saw using some scrap white melamine coated chipboard left over from a dismantled wardrobe. Having used it a few times to cut assorted sheet materials to size, I have identified that the track is sometimes a challenge to clamp in place due to the clamps getting in the way of the saw. This is particularly an issue when I’m trying to cut through thicker material and have the saw plunge depth set lower, so the motor of the saw sits closer to the surface of the track.

To resolve this, I had the idea of adding some extender pieces on the back of the track, which would allow me to clamp the track away from the path of the saw. I measured some scrap hardboard and cut it to size. I then used that hardboard to mark out a section on the back of the track and routed out a shallow section using my palm router and a straight bit.

I screwed the hardboard in place using some short screws into the thicker part of the track, where two pieces of chipboard overlap to provide decent holding power and the upgrade was finished!

I tested out the upgrade and found I can clamp the track to a range of sizes of material, with the two additional pieces of hardboard providing a range of clamping options, depending on where I position the clamps. Another quick and successful solution! 🔨