Knock-Down Cutting Support Grid

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buildsomething added on 6/10/2019

Make it easier and safer to cut boards and plywood down to size with this sturdy cutting support grid. Made from 2x2 boards, it spans between Kreg Mobile Project Centers, Track Horses, or one of each. Or you can modify it to work with about any sawhorse. Plus, it knocks down for compact storage.


Follow the steps below to complete this project.


Cut the Rail Parts

You can start by making the Lower Rails, as shown in the cutting diagram. We used #1 pine, but lesser grades will work, too. Just make sure the boards you choose are straight and free from twist. Even though the Lower Rails are 8' long, and the boards you’ll buy are 8' long. Check them. Sometimes the boards are slightly long, so you’ll want to cut them to length. Then, following the cutting diagram, cut four Upper End Rails, Four Outer Rail Fillers, and two Center Rail Fillers to length. If you’re using a circular saw for your cuts, check out the how-to video for tips on getting square cuts. We also cut four Riser Blocks to elevate the rail assemblies to the correct height in our Mobile Project Center and Track Horse.

 How To Make Square Cuts with a Circular Saw

Learn how to cut boards to length accurately using a circular saw, and get straight, square cuts. 


Assemble the Rails

Now you can assemble the parts to create the completed rails. We only used glue—no screws or nails. That way, when you’re cutting on the grid, you won’t have to worry about your saw blade hitting a nail or screw. Lay the parts out on your work surface, or on the floor, and make sure you have them all oriented correctly. Then glue each piece to the Lower Rails, using scraps of 2x2 as spacers to ensure proper spacing—but make sure you don’t accidentally glue the spacers in. You can clamp the pieces or wrap them with masking tape while the glue dries

 How To Choose and Use Wood Glue

Learn how to choose the right wood glue for your project, and get tips for applying it correctly.


Cut the Cross Bar Parts

Now you can cut the parts for the cross bars, as shown in the cutting diagram. You’ll need four Upper Cross Bars, four Lower Cross Bars, and eight Cross Bar Fillers. You can also cut two 2x4 Cross Bars. They’ll fit in the tracks on top of either the Kreg Mobile Project Center or Track Horse. If you’re cutting with a miter saw instead of a circular saw, check out the how-to video for information on using stops to more-easily cut multiple parts to the same size.

 How To Make Repeatable Cuts Using Stops

Learn how to use stops on a miter saw to ensure that you can easily cut multiple pieces to the exact same length. 


Assemble the Cross Bars

Now, using the same methods you used to assemble the rails, you can assemble the cross bars. Once again, use scrap 2x2s as spacers.


Test Fit and Sand

After the glue dries on the rails and cross bars, you can make sure the bars all go into the notches. If the rails and bars bind, sand the rail notches with 80-grit sandpaper to wide them a bit. The easiest way to do this is to wrap the sandpaper around the scrap piece of 2x2, place it in the notch, and sand. Then you can scrape off any excess glue and sand your new cutting support grid smooth, if desired.

Tools Used:

Materials Required:

Wood Products:

(8) 2x2, 96", Board  
(1) 2x4, 96", Board  


(1) wood glue Shop Online

Parts/Cut List:

(2) Lower Rail, 1 1/2" x 1 1/2" x 96" pine  
(4) Upper End Rail, 1 1/2" x 1 1/2" x 23 3/4" pine  
(4) Outer Rail Filler, 1 1/2" x 1 1/2" x 14 1/4" pine  
(2) Center Rail Filler, 1 1/2" x 1 1/2" x 14" pine  
(4) Upper Cross Bar, 1 1/2" x 1 1/2" x 42" pine  
(4) Lower Cross Bar, 1 1/2" x 1 1/2" x 31 1/2" pine  
(8) Cross Bar Filler, 1 1/2" x 1 1/2" x 3 3/4" pine  
(4) Riser Block, 1 1/2" x 1 1/2" x 1/2" pine  
(2) 2x4 Cross Bar, 1 1/2" x 3 1/2" x 31 1/2" pine  


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