Abstract:
A miter box fence system includes a fixed vertical portion and a movable portion that may be moved with respect to the fixed vertical portion. The movable portion includes a notch that allows one edge of crown molding to be placed in the notch while the other edge of the crown molding extends towards the fixed vertical portion. The movable portion may be moved with the crown molding in place until the crown molding makes appropriate contact with the bottom of the notch and with the fixed vertical portion. The movable portion may then be secured in place. Because the notch in the movable portion creates a stop for cutting crown molding, and because the notch is below the flat portion of the movable portion, the miter box fence system may be used to cut both crown molding and flat stock without modification.

Description:
BACKGROUND 
     1. Technical Field 
     This disclosure generally relates to woodworking tools, and more specifically relates to a fence for a miter box. 
     2. Background Art 
     Miter boxes have been used for many years by finish carpenters. A miter box allows a finish carpenter to cut angled cuts that provide attractive joints for a variety of different finishing work, such as window and door casings, baseboard, and crown molding. Cutting crown molding presents a unique challenge because crown molding is installed at an angle with respect to the wall and ceiling. As a result, cutting a traditional 45 degree angle in crown molding requires a compound miter cut, which means the saw blade is typically set at a first angle (such as 45 degrees) with respect to the miter box fence, and the blade is then tilted at an appropriate angle. Compound miter cuts create unique challenges for the finish carpenter for a variety of reasons. First, because crown moldings are made to be installed at different angles, a different compound miter cut must be used for each different angle of crown molding. For example, crown moldings that have a designed angle with respect to the wall of 38 degrees, 45 degrees, and 52 degrees are common. To make an appropriate compound miter cut, the finish carpenter must first determine the appropriate angle of the crown molding being used, then use a table that converts the angle of the crown molding to an appropriate blade tilt on the miter saw. Another challenge to cutting crown molding is the molding is laid flat and pressed against the fence, which is not representative of how it is installed. As a result, it is easy to get confused regarding which direction the cut needs to go, and whether the top or bottom of the crown molding is held against the fence. 
     Several devices have addressed some of the problems in cutting crown molding by providing various ways to hold crown molding at an angle while cutting, which eliminates the need for performing compound miter cuts. For example, if a 45 degree crown molding is held at a 45 degree angle instead of being held flat, a single miter cut is all that is needed instead of a compound miter cut. These devices can be classified as two separate types. The first type is a device separate from the miter saw that holds the crown molding at an angle while the saw cuts the crown molding. Examples of these are show in U.S. Pat. Nos. 6,481,320, D557,296 and D640,112. The second type is a fence system for a miter saw that provides stops on the horizontal part of the fence that allow placing crown molding between the stops and the vertical part of the fence at the appropriate angle. Examples of these are shown in U.S. Pat. Nos. 346,240, 752,406, 3,397,722, 4,875,399 and 7,726,224. Both of these types hold the crown molding at the appropriate angle while cutting, thereby eliminating one of the angles needed during the cut. This allows crown molding to be cut with a miter saw using simple miter cuts instead of using compound miter cuts. 
     One drawback of the second type of devices discussed above is the stops for the crown molding are placed on top of the flat surface of the fence. If the finish carpenter then needs to use the miter box for cutting flat stock such as a door casing, the device used to cut the crown molding must be removed. What is needed is a miter box fence system that allows cutting crown molding and that allows cutting flat stock without modification of the fence system. 
     BRIEF SUMMARY 
     A miter box fence system includes a vertical portion and a movable portion that may be moved with respect to the vertical portion. The movable portion includes a notch that allows one edge of crown molding to be placed in the notch while the other edge of the crown molding extends towards the vertical portion. The movable portion may be moved with the crown molding in place until the crown molding makes appropriate contact with the bottom of the notch and with the vertical portion. The movable portion may then be secured in place. Because the notch in the movable portion creates a stop for cutting crown molding, and because the notch is below the flat portion of the movable portion, the miter box fence system may be used to cut both crown molding and flat stock without modification. 
     The foregoing and other features and advantages will be apparent from the following more particular description, as illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       The disclosure will be described in conjunction with the appended drawings, where like designations denote like elements, and: 
         FIG. 1  is front view of a miter box fence system; 
         FIG. 2  is a cross-sectional diagram showing crown molding installed between a wall and a ceiling; 
         FIG. 3  is a cross-sectional side view of the miter box fence system taken along the line  3 - 3  in  FIG. 1 ; 
         FIG. 4  is a cross-sectional side view of the miter box fence system with a piece of crown molding; 
         FIG. 5  is a cross-sectional diagram showing crown molding installed between a wall and a ceiling; 
         FIG. 6  is a cross-sectional side view of the miter box fence system showing placement of the crown molding in  FIG. 5  into the miter box fence system, which results in an inaccurate fit; 
         FIG. 7  is a cross-sectional side view of the miter box fence system showing adjustment of the movable portion to provide an accurate fit for the crown molding; 
         FIG. 8  is a cross-sectional side view of the miter box fence system showing cutting of flat stock such as baseboard; 
         FIG. 9  is perspective view of the miter box fence system; and 
         FIG. 10  is a method for using the miter box fence system to cut crown molding. 
     
    
    
     DETAILED DESCRIPTION 
     A miter box fence system  100  is shown in  FIG. 1  to include a vertical portion  110  coupled to a movable portion  120 . Movable portion  120  is movable or adjustable with respect to vertical portion  110  to accommodate different sizes of crown molding. In the specific configuration shown in  FIG. 1 , the movable portion  120  is movably coupled to the vertical portion  110  using four bolts and using corresponding nuts. One of the four bolts with its corresponding nuts are shown in the cross-sectional side view shown in  FIG. 3 . 
       FIG. 2  shows a typical installation of crown molding  210  between a ceiling  220  and a wall  230 . The crown molding includes a first flat edge  212  that is placed flat on the ceiling  220  and a second flat edge  214  that is placed flat on the wall  230 , as shown in  FIG. 2 . The particular piece of crown molding shown in  FIG. 2  has an angle of 45 degrees with respect to the wall. Common angles for crown molding include 38 degrees, 45 degrees, and 52 degrees. 
     Because crown molding is installed at an angle with respect to the wall and ceiling, cutting crown molding when laid flat on a miter box fence requires making a compound miter cut. The angle of the compound miter cut will vary with the angle of the crown molding. The compound miter cut may be eliminated if the crown molding is held at the appropriate angle while being cut. 
     A cross-sectional view of the miter box fence system  100  in  FIG. 1  taken along the line  3 - 3  is shown in  FIG. 3 . The vertical portion  110  is preferably L-shaped as shown, and includes a vertical planar surface  310  and a substantially horizontal planar surface  320 . The movable portion  120  is adjustably coupled to the vertical portion  110  with a plurality of bolts  350  and a plurality of nuts  360 ,  370  and  380  in a configuration that allows adjusting position of the movable portion  120  with respect to the vertical portion  110 . The movable portion  120  includes a first planar portion  340  that is substantially coplanar with the substantially horizontal planar surface  320  of the vertical portion  110 . The movable portion  120  further comprises a notch  330  that comprises a substantially vertical surface  332  and a substantially horizontal surface  334  below the first planar portion  340 . While the reference designators for the notch  330 , vertical surface  332 , and substantially horizontal surface  334  shown in  FIG. 3  are not shown in  FIGS. 4, 6, 7 and 8  due to space limitations, it is understood that the notch shown in  FIGS. 4, 6, 7 and 8  is the same notch  330  with vertical surface  332  and substantially horizontal surface  334  shown in  FIG. 3 . 
     Crown molding may be cut using the miter box fence system  100  by placing a first edge of the crown molding into the notch  330  and by placing a second edge of the crown molding against the vertical planar surface  310 , as shown in  FIG. 4 . This holds the crown molding at the same angle when the crown molding is installed, eliminating the need to make a compound miter cut. The miter box fence system may be adjusted to accommodate different sizes of crown molding. Referring to  FIG. 5 , crown molding  510  has an angle of 38 degrees with respect to wall  230  and has a width greater than the width of crown molding  210  shown in  FIG. 2 . With the miter box fence system adjusted as shown in  FIG. 4  for the narrower crown molding  210  shown in  FIGS. 2 and 4 , placing the wider piece of crown molding into the slot as shown in  FIG. 6  results in a poor fit, with flat surface  512  of crown molding  510  not flat against the vertical planar surface  310  and with flat surface  514  not flat against the substantially horizontal surface  334  of notch  330 . This indicates to the user of the miter box fence system that the movable portion  120  needs to be moved to the right as shown by the bold arrow in  FIG. 7  until the flat surface  512  is flat against the vertical planar surface  310  and the flat surface  514  is flat against the substantially horizontal surface  334  of notch  330 , as shown in  FIG. 7 . This is accomplished by loosening nuts  370  and  380  that attach the movable portion  120  to bolt  350 , and turning the nut  380  to allow the movable portion  120  to move to the position shown in  FIG. 7 . Once the movable portion is positioned as shown in  FIG. 7 , the nuts  370  and  380  are tightened to captivate the movable portion  120  in the proper position for this particular crown molding. At this point the finish carpenter can use the miter box fence system  100  to make whatever cuts are needed on the crown molding without having to make compound miter cuts. 
     One of the advantages to the miter box fence system  100  is the finish carpenter can visualize what cut to make based on the orientation of the crown molding. Thus, in the configuration shown in  FIG. 7 , if the finish carpenter visualizes the vertical planar surface  310  as the ceiling and the substantially horizontal surface  334  as the wall, the direction of the cut that is needed is easily determined visually. This reduces the errors that often result from making compound miter cuts. 
     One significant advantage of the miter box fence system  100  is the ability to cut flat stock such as baseboard  810  without making any changes to the miter box fence system  100 , as shown in  FIG. 8 . All known miter box fence systems that are used for crown molding do not allow cutting flat stock without modification. The baseboard  810  bridges the gap between the vertical portion  110  and the movable portion  120 , resting on the coplanar surfaces so the flat stock may be cut using the miter box.  FIG. 9  shows a perspective view of the miter box fence system  100 . 
     The miter box fence system  100  may be made of any suitable material, including wood, plastic, metal, composite or synthetic materials, etc. The most preferred materials are wood and plastic, which provide the necessary rigidity while allowing a miter saw to easily cut the miter box fence system  100  that is directly under the blade. 
     The miter box fence system  100  may be used on motorized miter saws or on manual miter saws. The miter box fence system  100  may be attached to the miter saw in any suitable way, such as using nuts and bolts to couple the vertical portion  110  to a corresponding vertical fence on the miter saw. This could be done, by way of example, using flathead screws that extend through the vertical portion then through corresponding holes in the vertical fence on the miter saw, thus recessing the flat heads below the vertical planar surface  310  so the screws do not interfere with use of the miter box fence system. Of course, wing nuts could replace the hex nuts shown in the figures to make it easier to adjust the movable portion by hand without using tools. 
     Various fasteners could also be used to movably couple the movable portion  120  to the vertical portion  110 . Nuts and bolts are shown as one example, and any suitable fastener could be used for coupling the movable portion  120  to the vertical portion  110  in a way that the movable portion may be moved or adjusted, then fixed in the adjusted position. For example, the internal portion of movable portion  120  could be threaded. In this configuration, access to the head of the bolt from the back side of the vertical portion would allow a user to turn the head of the bolt to move the movable portion. Another possible configuration is to use smooth rods instead of bolts, with friction push nuts that have a release mechanism. In addition, the number of fasteners could vary. Thus, while the figures show four bolts, any suitable number of fasteners could be used. In addition, a more complex design is clearly within the scope of the disclosure and claims herein. For example, the movable portion  120  could be movably coupled to the vertical portion  110  using a track and rail system, similar to a drawer sliding on drawer guides, with a locking mechanism to lock the movable portion  120  in a desired position. The disclosure and claims herein expressly extend to any suitable fastener, number of fasteners, and mechanisms that can couple movable portion  120  to vertical portion  110  in a way that is adjustable, yet allows fixing the movable portion  120  in a desired position. 
       FIG. 10  shows a method  1000  for using the miter box fence system to cut crown molding. One edge of the crown molding is placed into the lower slot of the movable portion, with the opposite edge touching the vertical portion (step  1010 ). When the opposite edge is flat against the vertical portion (step  1020 =YES), such as shown in  FIGS. 4 and 7 , the cut may be made with the miter box (step  1060 ). When the opposite edge is not flat against the vertical portion (step  1020 =NO), such as shown in  FIG. 6 , the fasteners on the movable portion are loosened (step  1030 ), and the movable portion is adjusted or moved until the opposite edge of the crown molding is flat against the vertical portion (step  1040 ). Note that once the opposite edge of the crown molding is flat against the vertical portion, the edge in the slot will also be flat against the substantially horizontal surface of the slot. Once the movable portion is in the proper position, the fasteners are tightened to secure the movable portion in the desired position with respect to the vertical portion (step  1050 ). The cut is then made (step  1060 ). 
     The miter box fence system provides an easy way to cut crown molding using a single miter cut instead of a compound miter cut. The finish carpenter can easily visualize what cut needs to be made because of the orientation of the crown molding. In addition, flat stock may be cut without any changes to the miter box fence system. 
     One skilled in the art will appreciate that many variations are possible within the scope of the claims. Thus, while the disclosure is particularly shown and described above, it will be understood by those skilled in the art that these and other changes in form and details may be made therein without departing from the spirit and scope of the claims.