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Jaime Costiglio

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How to Make a Wedge Jig

October 29, 2014

This is definitely a chicken before the egg situation.  While embarking on the wood star project I quickly realized I needed a wedge jig in order to make a steep miter cut so I made one and I’m sharing the how-to with you.
wedge jig to make stars

Let’s make a wedge jig for your miter saw. A DIY tutorial to create a wedge jig for making steep cuts on a miter saw plus a wood star project.

If you saw the recent Pottery Barn catalog chances are you love these wood stars as much as me:
pottery barn milled wood stars
image source
And you quickly thought ‘I can DIY that surely!’.  However after much trial and error I consulted fellow buildy blogger Jamison at Rogue Engineer who quickly informed me I needed a 54 degree angle in order to make the five pointed star shape.
BUT MY MITER SAW DOESN’T MAKE A 54 DEGREE CUT?
Never fear I have the solution.  If you want to make a five pointed wood star you are going to need a wedge jig and I’m going to show you how to make one because I googled it to death and couldn’t find a tutorial :).  PS – I have a new fancy miter saw set up that makes a 60 degree cut!!  But this tutorial below is still great for make a wedge jig if you need any steep cut beyond the capacity of your miter saw.
This jig is made using wood scraps from around the shop, no need to buy any supplies just use what you have on hand.  It’s a jig after all and although extremely useful it’s not decorative so don’t worry about being fancy here.
Supplies:
  • 3/4″ scrap plywood
  • 1×2 pine board scrap
  • 2″ wood screws
  • wood glue
  • protractor
  • pencil
  • miter saw
  • drill & drill bits
 
supplies to make a wedge jig
(You don’t need a measuring tape for this project but somehow it ended up in the picture.)
The wedge jig can be used for most miter cuts that exceed your saw’s settings.  In this case we are making a jig for 54 degrees but you can make this jig to fit your necessary miter cut.
Essentially we are moving the fence forward to make a steeper angle.
Below is the tutorial to make a wedge jig for your miter saw.  Please read through all the steps before beginning to understand the process.  Also this is what worked for me and maybe you have a better version or an update, please feel free to add your notes in the comments.  It’s very helpful to others when the can see your insights – thank you!
miter saw set at 30 degrees
Step 1: Set your miter saw for a 30 degree miter cut.  I choose 30 degrees because it seemed like good middle ground, not too steep.
cut plywood at 30 degree miter
Step 2: Set the 3/4″ plywood scrap flush to fence and make the cut.
mark plywood at 36 degrees
Step 3: Go old school and use a protractor to mark a 36 degree angle off of the fresh miter cut.  The goal is to get up to a 54 degree miter cut so 90 – 54 = 36.
draw line on plywood at 36 degrees
Step 4: Draw a line for the 36 degree angle from the red dot through your mark.
attach fence at line
Step 5: Glue and attach the 1×2 pine board on the narrow side flush up to the line you just drew (in red above).  Predrill and countersink 2″ wood screws down into the 1×2 board.  Don’t worry if the 1×2 extends off the plywood at this point.
cut excess fence from plywood
Step 6: Reset the miter back to 0 degrees and cut the excess 1×2 flush to the plywood.  Do this for both ends of the 1×2.
wedge jig complete
Your wedge jig is complete and ready to use.
Don’t forget to set the miter back to 30 degrees before making any cuts!
 
attach jig to saw using clamp
Also be sure to use a clamp to keep the jig secure.  If you want additional security consider adding a perpendicular wood fence to the plywood (where it meets the saw fence) then you can clamp the wood fence to the saw fence as well.
clamp board to jig
Now place the board to be cut in front of the wedge – here I used about an 8″ piece of 1×3 pine.  Be sure to clamp the board to the wedge fence and cut away.
54 degree miter done on a miter saw using a wedge jig.
 
Now you can make these wood stars in my post here.
diy wood stars
SHOP THIS PROJECT:
 

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Filed Under: DIY, SCRAP WOOD, TOOLS31 Comments

Reader Interactions

Comments

  1. Rebecca Mimnagh says

    October 30, 2014 at 4:43 PM

    So clever! I never could've even dreamed this up! I've had to do a few cuts that weren't 'set' on my miter saw and ended up using a protractor and probably a very dangerous cutting method…you've single-handedly saved me time and possibly a few fingers!!

    Reply
  2. Deez Nailz - Canadas most fabulous hand model says

    November 8, 2014 at 3:06 PM

    wow ~ thanks for posting this thurough tutorial. love your blog!

    Reply
  3. Kellie says

    December 5, 2014 at 3:21 AM

    We made these! My husband figured out to change the angle of the wedge jig slightly so that he wouldn't have to keep resetting the miter saw angle after each cut. Instead of 30 degrees he put the miter saw at 36 and made the wedge jig to accommodate the difference. Then the miter saw is all set for the 36 degree cut. 🙂 Thanks for the instructions!

    Reply
    • Unknown says

      June 25, 2017 at 7:04 PM

      I am trying my hardest to understand your comment so it makes life easier, but what angle did he put the wedge jig at to compensate? I am so lost in math it's infuriating. I know it's a very old comment, but perhaps you'll see it 🙂

      Reply
    • Anonymous says

      June 30, 2017 at 5:50 PM

      The angle from the edge of the jig needs to be 36 degrees no matter what angle you decided use for the edge of the jig.

      Reply
  4. Peter says

    December 21, 2014 at 3:59 PM

    Thanks for the tutorial. Always battled with angles larger than 45 degrees. Going to improve the jig though and will share with all. I have thought of a way the jig can be fully adjustable from 45 to 90 degrees so that you don't have to reset the machine all the time. Thanks for the foundation.

    Reply
    • gloria deaver says

      November 12, 2017 at 10:14 AM

      PETER CAN YOU SHARE THE ADJUSTABLE JIG YOU MADE FOR ALL OF US? THANKS

      Reply
  5. Tad Thies says

    February 11, 2016 at 11:14 AM

    What was the size of the plywood that you started with? i am guessing 24×18?

    Reply
  6. The Kindergarten Pod says

    January 17, 2017 at 3:09 AM

    I am a new follower! Love your blog and your ideas! Can't wait to make these stars 🙂

    Reply
  7. Trevor says

    October 24, 2017 at 5:03 PM

    Ugh…..I’m not doing something right. It says to nail the short piece to the long piece. Shouldn’t they all be the same size? Each piece 6” ?
    So, you use the jig and cut at 30 degrees. Then remove jig and flip board……so that your just using the mitre saw. Change to 36 degrees and make the second cut?

    Reply
  8. Greg says

    February 1, 2018 at 1:23 PM

    The one thing I’m not following is why you cut the plywood on an angle. Couldn’t it have stayed squared off, and make your 36 degree jig from the edge?

    Reply
    • Jaime says

      February 3, 2018 at 3:02 PM

      Hi Greg, the reason for the initial cut on the plywood at an angle is so that your 36 degree fence is not so steep. Yes you could probably leave the plywood square and attach the fence no problem. For some reason that’s just how I did it. Thanks for chiming in, always good to hear other’s ideas.

      Reply
  9. Eric Kelley says

    September 9, 2018 at 12:00 PM

    Although I am not a fan of miter saws, ( I have never figured out what I could do with one that I couldn’t do quicker, or easier with a table saw, or radial arm saw), I do like this jig for this application . One thing which could possibly improve it, would be to make it adjustable, so it could be used for other angles on the same jig.

    Reply
    • sheryl wince says

      September 16, 2020 at 5:48 PM

      Can you share how you did this on the table saw?

      Reply
  10. David says

    December 2, 2018 at 7:59 PM

    I still don’t understand how the 56 degree cut will happen with a 36 jig and the mitter setting left at 30.
    Do I need to move the mitter setting to Be able to cut the 56 degree? Example 54-36=18?

    Reply
    • Jaime says

      December 3, 2018 at 6:05 AM

      Hi David, For this project we need a 54 degree angle. 90-54 = 36. The 30 degree cut is arbitrary, you can make the jig using any angle you like. I picked 30 because it seemed good middle ground. Make the 36 degree mark off of that cut angle and then keep your saw at that angle (30 or whatever you choose) to make the steeper cuts using the jig. Hope that helps.

      Reply
  11. kj says

    January 14, 2019 at 2:54 PM

    make a 18 degree jig instead, set your miter saw to 36 degree to make 54 degree angle.
    then remove jig for 36 degree angle.
    would it be easier?

    Reply
    • Jaime says

      January 15, 2019 at 6:17 AM

      Hi Kj, Yes you could definitely go this route. 18 is pretty shallow – I just choose 30/36 because it seemed good middle ground.

      Reply
  12. Wilson says

    August 2, 2019 at 11:41 PM

    Question, why not just make a right angle out of wood and just use that. All you have to do is set the miter saw to 36 degrees and never move it again. Make your 36 degree cut (board is on its skinny side, body against the fence of the miter saw) Then put the right angle on the left side of the board you just cut, basically like an upside down, backwards L (uncut end of board towards saw blade, still laying on its skinny side, small uncut end against miter saw fence) then that will give you your 54 degree cut. Clamp the board to the right angle jig for stability if needed.

    Reply
  13. pedro says

    December 10, 2019 at 2:43 PM

    I hate angles unfortunatly i have to deal with them everyday

    Reply
  14. JOSHUA says

    April 10, 2020 at 8:03 AM

    Is a “sliding” miter saw required?

    Reply
    • Jaime says

      April 11, 2020 at 8:22 AM

      Hi Joshua, Depends on how wide your miter saw will cut. Technically no you don’t need a slider but your base piece of plywood will be shorter because the stationary saw can’t make as long a cut as a slider.

      Reply
  15. Giancarlo Cancelliere says

    August 12, 2020 at 3:23 PM

    Hi – love the idea of using the jig – just curious why you chose not to use an 18 degree angle for the star points? Is it easier to build this way? Am I right in thinking the 2 angles you are aiming for are 54 degrees and 36?

    Reply
  16. Bruce356 says

    November 20, 2020 at 9:08 PM

    Hi Jamie,
    I don’t know if you are still monitoring your posts but if you are I could really use your help. I followed your instructions precisely and the angle of the where I affixed the 1X2 is exactly 36 degrees (per my nifty new birthday digital gauge that my wife bought me.)

    Now for the dumb question. I understand the first 36 degree cut using the jig, but how do you make the 54 degree angled cut? I know this is the whole point of the jig so clearly I am missing something. (It could also be that I am not getting enough fresh air through my mask and depriving my brain of much needed oxygen)! (-:

    Thank you for your help and kind assistance.

    Reply
    • Jaime says

      November 21, 2020 at 7:41 AM

      Hi Bruce, to make the 54 degree cut we are moving the fence forward (making it steeper) with the jig. Check the last process step photo – see how the new fence pushes the lumber forward (towards you) and is capable of making a steeper cut safely. Be sure your miter is set to 30 degrees first, clamp the jig in place and then clamp the board to the jig fence. I hope that helps.

      Reply
  17. MTS says

    September 15, 2021 at 2:15 AM

    You don’t need a jig at all. Just set your saw to 36* and make your cut. 0 on the saw is actually a 90* cut. 10* is actually 80*. 20*=70* 30*=60* 36*=54* cut.

    Reply
    • Erika says

      November 4, 2022 at 11:49 PM

      Osea tú dices que haga todos los cortes en 36° y lista mi estrella…

      Reply
  18. Mark Finklestein says

    December 11, 2021 at 1:50 PM

    My angles are not matching up and the lengths are different than stated. Made the jig per instructions but????? Don’t know what I am doing wrong.

    Reply
  19. Ej says

    December 2, 2022 at 9:46 AM

    Can this jig be used on a table saw?

    Reply
    • Jaime says

      December 5, 2022 at 6:53 AM

      No this jig is not set up for use on a table saw.

      Reply
      • Earnestine Johnson says

        December 5, 2022 at 6:33 PM

        Bummer :(. Thanks

        Reply

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