Saw the Clamp Block
1. Mill the clamp block (A, Fig. A, below) to final thickness and width, but leave it 12 in. long. Drill holes for three threaded inserts (Fig. E, below).
2. Make the clamp’s dovetail slot in three steps (Fig. B). Tilt the tablesaw blade to 10 degrees and make Cut 1. Install a 5/8-in. dado blade for Cut 2. Remove the remaining waste with a chisel. Trim the dovetail to length with Cut 3. Cut the clamp block to final length. Save the long offcut for later use.
3. Predrill and install four screws to strengthen the dovetail. Without the screws, the fence could break if you overtighten the clamp.
4. Install the threaded inserts flush to the surface.
Make the Rails
5. Mill the front and back rails (B and C) to final dimensions. Tilt the saw blade to 10 degrees and cut the dovetail angle on the front rail (Fig. F, Cut 1, below). Return the blade to 90 degrees to cut the remaining section of the dovetail (Fig. F, Cut 2).
6. Mark and drill holes for mounting the rails to your bandsaw. Most bandsaw tables have predrilled holes for mounting accessory fences. It’s vital that the top of the clamp block, when attached to the front rail, is level with the top of the bandsaw table. The easiest way to ensure this is to remove the table from the bandsaw. To do so, unscrew the knobs below the table trunnions and lift the table straight up and off.
7. Place the table upside down on a flat surface (Photo 1). Assemble the clamp block, its offcut and the front rail so the dovetails interlock. Turn them upside down and place them next to the front of the table. Align the rail with the right side of the table and transfer the position of the table’s holes. Move the rail so it lines up with the table’s left side and mark the holes again. Repeat for the back rail, without using the clamp blocks.
8. Drill the four bolt holes in both rails on the drill press. Turn both rails over and counterbore these holes using a Forstner bit.
9. Cut the wear-strip rabbet in the front rail (Fig. F). Cut a dado on the back rail for the table’s miter gauge (Fig. A). Bolt both rails to the table. Replace the table on the bandsaw.
10. Drill and countersink screw holes in the wear strip. Mount the wear strip on the front rail.
Build the Fence
11. Lay out the fence base (Fig. G, page 66). Cut the curved slots with a jigsaw. Use a Forstner bit to drill two holes for bronze bushings. Epoxy the bushings into the holes. Cut the outside profile.
12. Make the fence face (E) and braces (F). Glue, but don’t screw, the face and braces to the base. Wait overnight for the glue to dry; then joint the fence square (Photo 2). Add four screws to reinforce the glue joint.
13. Install a locking knob on the clamp block. Place the clamp block on the front rail. Attach the fence to the clamp. Remove the blade from the bandsaw and align the fence with the table’s miter slot. Tighten the clamp and fence. Drill the index pin hole through the fence base and the clamp.
14. For most cuts, keep the fence on the left side of the blade. For extra rigidity, use a C-clamp to fasten the fence base to the back rail. To put the fence on the right side of the blade, unscrew the fence from the clamp, turn it around and remount it. To extend the rails past the table’s right side, remove the wear strip, unbolt the rails from the table and remount the rails using the second set of holes.