How to Make an Angle-Cutting Tool for Hacksaws

  • By: Monica Shulz

Cutting guides are a great way to achieve clean, straight cuts with a hacksaw or other cutting tools. It helps keep the blade straight throughout the cut and stops it from deflecting.

In this article, we’ll show you how to create a cutting guide for making angled cuts on workpieces. You’ll be able to cut clean, angled edges consistently on your workpieces using this tool.

So, let’s get to the workshop and create this tool.

What You’ll Need

To create the cutting guide, here is a list of the items you’ll need:

  • 10cm x 4cm Rectangular Halfpipe
  • 8cm x 2cm Rectangular Pipe
  • 3cm x 2cm Solid Rectangular Metal Block
  • 8cm-Long 1cm-Thick Solid Pins
  • 5mm Thick Sheet Metal
  • M10 and M4 Socket Screws

Drill The Holes For The Guides In The Base

Place the 50cm long 10cm x 40cm rectangular half-pipe on the workbench. This will be the base for the angle-cutting tool.

Divide it into 25cm sections by drawing a line straight down its middle.

Mark two holes about 10cm away from the middle line right in the middle. Mark another two points 20cm away from the middle line on both sides of the line.

Make sure all the points are right in the middle of the halfpipe. Drill the points through with an M4 tap bit.

Drill The Hole For The Arm

On the middle line you drew, mark a point about 1.5cm away from the base. Drill that point through using a 1cm tap bit for a threaded hole.

Mark Out The Holes In The Arm For Drilling

Place the 2cm x 3cm metal rod on the table and cut a 15cm long section from it. This will be the arm of the angle-cutting tool.

Next, divide the 3cm wide face into two sections by drawing a line straight down its middle. First, mark out a point away from the bottom of the

Mark out two points 7mm from the bottom of the face. One point should be 7mm away from the middle line on the right, and the other should be 7mm away from the middle line on the left.

Next, mark these same two points about 7mm from the top of the face. Mark out another two sets of points about 30mm from the first set at the top.

Now, you should have two pairs of points at the top and one pair and one single point at the bottom.

Drill The Holes In The Blank

Remember the first hole you marked in the middle of the blank? That’s what you’ll drill first. Drill it to a depth of 10mm using a 17mm wide drill bit.

After this, drill it all the way through at the same point using a 10mm tap bit.

Next, drill the remaining six holes through to the other side using a 7.5mm drill bit. Make sure you clear the holes of any kerf or debris.

Prepare The Guide Pins

Take one of the 8cm long pins and mark a 2cm section on one end. Using a grinder, reduce the diameter of the section to 7.5mm.

Do the same for the remaining three pins.

Add The Arm to The Base

Take the cutting guide’s base and place it on the workbench. Take the arm and place it directly in the middle of the base and make sure the 10mm holes on both pieces line up.

Secure them together using an M10 socket screw. Make sure you tighten it properly. Also, test the arm.

It should still be able to move freely with no friction.

Cut Out the Guides

Take the 8cm x 2cm rectangular pipe and place it on the workbench. Measure, mark out, and cut two 30cm sections from the rectangular pipe.

Draw a 45-degree from one of the edges of the line. Use a chop saw to cut off the 45° section. Do the same for the second section.

Now, you should have two sections with one angled 45° side.

Drill Screw Holes in The Guides

Rotate the arm on the base, forming a 45 angle with the left side of the base. Use the left edge of the arm to draw a 45-degree line on the base.

Repeat the same thing for the right side with the arm. Next, place the guides on the base and ensure their angled edges line up with the lines you drew on the right and the left.

Make sure the guides are right in the middle with 1cm of space on either side. After this, clamp them to the base and turn the base over.

Mark where the screw holes on the base intersect with the bottom of the guides. You should have two points on each guide.

Drill the guides at both points using an M4 tap bit.

Attach The Guides To The Base

Once you’ve drilled the holes in the guides, place them back on the base. Make sure the holes on them line up with the holes on the base.

Now, join the guides to the base using some M4 socket screws. Make sure you tighten the screws properly so the guide stays in place.

Cut Out the Backing For The Guides

Place the 5mm thick sheet on the workbench and mark two 30cm x 8cm sections on it. Cut them out using an angle grinder.

Clean the edges of the plates with a grinder to remove any burrs.

Drill The Holes On The Guides

Place one of the backings on the workbench. Mark out two points about 5mm from the left and right sides.

These points should be 10mm away from the bottom edge. Do the same for the second backing.

Drill all the points on both backings through with an M4 tap bit.

Drill Holes For The Backings On The Guide

Place one of the backings against the bottom of the left guide. Make sure it lines up correctly with the guide and is on the same level as the base.

Mark out where the holes on the backing intersect with the guide using a marker. Do the same with the other backing and the right guide.

Unscrew the guides from the base and drill them through with an M4 tap bit at the points you marked.

Assemble the Angle Cutting Tool

Place the base back on the workbench. Secure the arm back to the base with the M10 socket screw. Next, place the pins into the holes on the base.

Make sure you put the ground 7.5mm ends in. Tap them in with a mallet in case they have trouble entering all the way.

Next, place the left and right guides on the base and secure them with M4 socket screws. Tighten these screws properly.

Once the guides are in place, take the backing and attach them to the guides using some M4 socket screws. Tighten the screws properly,

Viola, your guide is done.

Final Product

Now your cutting guide is ready for use! Using this helpful tool, you can make angled 45° cuts quickly without needing extensive marking and setting up.

It will also help keep your blade on course resulting in a smooth, easy cut.

You can check the Adaptor channel on YouTube for more great tools like this. They have several good DIY videos for all skill levels.

Photo by ADAPTOR / CC BY 3.0