For anyone working with picture frame moulding, achieving clean, precise mitre cuts is essential for a professional finish. Wide or undercut mouldings can present a particular challenge. Traditional methods or less refined tools can lead to tear-out, time-consuming adjustments, and the need for extensive filling. One content creator discovered a solution by developing a DIY double mitre saw rig, highlighting the importance of blade selection for optimal performance.
Initially, a Morso was used for chopping moulding, which was adequate but slow and resulted in chipping, especially on the back of the moulding. This spurred the idea for a more efficient setup using chop saws. A single, inexpensive chop saw was tested but proved inaccurate, requiring manual truing of mitres. The thought evolved to using two chop saws, one set for each mitre angle, to eliminate the need to swing the saw head and improve accuracy. For this permanent setup, Makita saws, specifically Japanese-made models (to avoid potentially less precise Chinese versions), were chosen for their quality and lack of a compound slide, which was deemed unnecessary and potentially less accurate for this fixed application.
The dual Makita saw rig, combined with a custom measuring scale, was assembled for under £500. This setup immediately provided significant benefits. The fixed angles of the two saws increased efficiency and consistency. While the initial setup was effective for plain wood and gesso-only mouldings, the blades played a crucial role in the quality of the cuts.
The original 24-tooth blades supplied with the saws were quickly replaced with 80-tooth blades. Although not a top-tier brand, these affordable, fine-tooth blades were tested and proved to be a game-changer. This upgrade significantly reduced tear-out and chipping, especially on the delicate backs of mouldings, a problem previously encountered with the Morso. These blades have been in use for three years, processing thousands of feet of moulding without needing sharpening, demonstrating their durability and the effectiveness of fine-tooth blades for this application.
While a professional double mitre saw rig is undoubtedly ideal, the DIY solution offers a cost-effective and highly functional alternative. The key takeaway for anyone seeking the best results in picture frame moulding is the importance of a fine mitre blade. For 2024, focusing on high tooth count blades, like 80-tooth options, can significantly improve cut quality and reduce finishing work, regardless of whether you are using a dedicated double mitre saw or a creative DIY setup. This experience underscores that the right blade is a critical component in achieving professional-level mitre joints in picture framing.
