Author Topic: Guitar Resaw Jig  (Read 445 times)

0 Members and 1 Guest are viewing this topic.

Offline PortlandGuitar

  • Posts: 2
  • We are custom guitar makers
    • Portland Guitar
Guitar Resaw Jig
« on: June 20, 2020, 03:42 PM »
Last month we bought a substantial amount of rosewood boards in various sizes. We need to resaw them into backs and sides. Services that provide this in the Portland area were a good thought, but it would be expensive. The next idea was to upgrade from our 2hp machine to a 5hp machine. This would allow the speed of the resawing to be faster. Either way a resaw sled would be needed to hold the wood in place and to run it through the band saw. 
The plan is to get two rails and put sliders on them, mount this to the band saw table then use a pusher with compressible but rigid bumpers to hold the wood.
Jay is excited to start a new project. Going to the hardwoods store is like being a kid in a candy shop. He decided to get some high quality 13-ply plywood. He’s using his circular saw to cut up the board into appropriate pieces.

Cutting on the chop saw.

Here are the rails that will be used. They are bosh T-slots. The sliders on them are smooth, the plate will provide a good surface area for the board.

First the bottom beam was mounted. If the beams aren’t parallel the sliders will veer off and the plate holding the wood will not slide. To make the beams parallel these steel gauge blocks were stacked at each end and the other beam was placed on top of it then was fasten in place.

The sliders work seamlessly.

Smooth. The part on the right on the blade, holds two rollers to assist in the slide. They sit on silicone bumpers the are stiff but still have some give. These help push the board in and hold it in place.

The back holding the rails is clamped into the band saw bed. The angle that this piece is at will affect how straight the outcome will be. To provide wiggle room two bolts are put in the back that act as set screws and are perfect for adjusting the angles.

It’s hard to hold and push the board for 20 minutes to achieve one set. At that rate it takes a lot of patience, when that wears out, it’ll be worth it to purchase a high-power machine. To fix this problem and automate the system a pulley with a weight on the ended was added to provide enough force on the board to pull it through the blade. We can now walk away from it while it works. The amount of force needed to pull the board is small, so a five-pound weight suffices.


Here it is working up close.

The complete project. The wood we resaw rests on a 12-inch piece of wood on the sled. This lets the clamp work.

The result is good. We get about .22 in at one end. And .20 at the other. 10% variance is acceptable.


As more experience is gained using the jig and with different woods it will become easier. The next wood used will be box wood to make purfling.


Check out the jig videos at Portland Guitar Jig Videos

Festool USA does not pre-approve the contents of this website nor endorse the application or use of any Festool product in any way other than in the manner described in the Festool Instruction Manual. To reduce the risk of serious injury and/or damage to your Festool product, always read, understand and follow all warnings and instructions in your Festool product's Instruction Manual. Although Festool strives for accuracy in the website material, the website may contain inaccuracies. Festool makes no representations about the accuracy, reliability, completeness or timeliness of the material on this website or about the results to be obtained from using the website. Festool and its affiliates cannot be responsible for improper postings or your reliance on the website's material. Your use of any material contained on this website is entirely at your own risk. The content contained on this site is provided for informational purposes only and does not constitute professional advice.


Offline Alex

  • Posts: 6556
Re: Guitar Resaw Jig
« Reply #1 on: June 20, 2020, 04:37 PM »
Welcome to the forum, as an avid guitar player I always like to see how they get build. I guess there's a lot of jigs involved in the whole process. Hope to see more from you guys.

Offline Rob Z

  • Posts: 993
Re: Guitar Resaw Jig
« Reply #2 on: June 21, 2020, 02:56 AM »
Wow, what a cool jig. I watched the two videos and they are short  [smile] but interesting.  I love the look of rosewood and had stereo speakers for many years that were built of rosewood.

Offline AnthonyE

  • Posts: 3
Re: Guitar Resaw Jig
« Reply #3 on: July 07, 2020, 11:16 AM »
What are the sliders?  The 80/20 extrusion parts list is such a rabbit hole that I struggle finding actual parts that fit my needs.  Could you or someone point me in the direction of the sliders you are using for this jig? 

Offline Cheese

  • Posts: 7387
Re: Guitar Resaw Jig
« Reply #4 on: July 07, 2020, 01:05 PM »
What are the sliders?  The 80/20 extrusion parts list is such a rabbit hole that I struggle finding actual parts that fit my needs.  Could you or someone point me in the direction of the sliders you are using for this jig?

Go to the "Add-on Components" section of the 80/20 catalog and look under "Linear Motion".  They're called linear bearings.