Struggling with Perfect 45-Degree Cuts for Box Making
Asked by CraftyNinja85
Hey folks! I'm having some trouble achieving perfect 45-degree miter cuts for my box-making projects. No matter what I do, I always end up with gaps when I try to fold the box. I'm currently using a Dewalt 7485 table saw. I know it's not the best for precision work, but it's what I have space for right now. I've also tried building a shooting board for my hand plane, but I can't seem to get a single accurate 45-degree cut out of my saw. I even considered upgrading to a compact saw with a blade bevel adjustment wheel to improve my results. Any tips or tricks that I'm missing to nail those 45s? I also use a Wixey digital angle finder, but it's not giving me accurate measurements.
Answers
I recently upgraded from a similar job site saw, and one of the biggest improvements came from switching to a full kerf, high-quality blade. That made a noticeable difference in my cuts. Once I got a miter sled, the results were even better. But honestly, I didn’t see a huge difference until I invested in a larger cabinet saw, which really isolates the blade from vibration. If you’re still using a job site saw, you might be pushing it a bit beyond its limits!
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Have you thought about using a shooting board? It can help fine-tune your cuts if you get the angle close enough initially. Check out these videos for setup tips: [Video1](https://youtu.be/YnYczLJscYw?si=k6fj0gSXEw3ovXbq), [Video2](https://youtu.be/3odXnkR2N7s?si=aQOV8Llbbny6YEZv).
CraftyNinja85: Thanks for the links! I built a miter shooting board but still struggle with getting that 45-degree angle right. No issues with 90-degree cuts, though.
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When you're cutting, try taking off 99% of the material with your first cut and then shave off the last 1/32 inch on a second cut. It can help to get that precision you're looking for!
CraftyNinja85: Thanks! I’ll definitely give that method a try!
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You don't need a perfect 45-degree cut to use a shooting board. If you get it pretty close, you can adjust the angle using the lateral adjuster on your plane. Having a blade with no camber really helps too—in my experience, you'll still get great results even with a slight camber if the stock's not too thick.
CraftyNinja85: Good point! I didn’t think about using the lateral adjuster for that. I worked hard to get the sole of the plane perfectly square, though! Definitely going to try your suggestion.
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WoodworkerSam: Yeah, I've felt like I've maxed out my job site saw too. Thinking about holding out for a cabinet saw instead of another job site model.