Difference between revisions of "Cut Plywood"
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If you plan on doing any kind of construction or carpentry, you will eventually have to cut some plywood. Plywood can be unwieldy and may be challenging to cut, especially if you don't have the right tools. You can cut plywood with a circular saw or a table saw with ease, as long as you remember a few basic rules. Make sure you have a sharp blade in your saw, and take precautions to keep the sheet stable. | If you plan on doing any kind of construction or carpentry, you will eventually have to cut some plywood. Plywood can be unwieldy and may be challenging to cut, especially if you don't have the right tools. You can cut plywood with a circular saw or a table saw with ease, as long as you remember a few basic rules. Make sure you have a sharp blade in your saw, and take precautions to keep the sheet stable. | ||
| − | [[Category:Woodworking]] | + | [[Category: Woodworking]] |
== Steps == | == Steps == | ||
=== Cutting Plywood with a Circular Saw === | === Cutting Plywood with a Circular Saw === | ||
| − | #Choose the right kind of blade. To get a smooth cut on a sheet of plywood, you'll need to have the right blade. Look for a carbide-tipped blade with a high tooth count.<ref>http://ana-white.com/2015/03/tips-cutting-plywood-circular-saw#</ref> | + | #Choose the right kind of blade. To get a smooth cut on a sheet of plywood, you'll need to have the right blade. Look for a carbide-tipped blade with a high tooth count.<ref name="rf1">http://ana-white.com/2015/03/tips-cutting-plywood-circular-saw#</ref> |
| − | #* You can find blades labeled for plywood or "finished cuts," but make sure to check the tooth count.<ref | + | #* You can find blades labeled for plywood or "finished cuts," but make sure to check the tooth count.<ref name="rf1" /> |
| − | #* Blades come in various sizes, so be sure you get one that will fit your circular saw.<ref | + | #* Blades come in various sizes, so be sure you get one that will fit your circular saw.<ref name="rf1" /> |
| − | #* If you stick with the blade that came with your saw, you'll likely end up with splintered ends, also known as tear-outs.<ref>http://www.bobvila.com/articles/cutting-plywood/#.VjqNIaKQawo</ref> | + | #* If you stick with the blade that came with your saw, you'll likely end up with splintered ends, also known as tear-outs.<ref name="rf2">http://www.bobvila.com/articles/cutting-plywood/#.VjqNIaKQawo</ref> |
| − | #Set the saw blade to the right depth. Before cutting your plywood, adjust your saw blade to the right depth. If your blade is set too deep, you'll be dragging a lot of excess blade through the sheet. If you have your blade set too shallow, you run the risk of not cutting all the way through the sheet.<ref> http://www.familyhandyman.com/tools/circular-saws/how-to-cut-plywood/view-all</ref> | + | #Set the saw blade to the right depth. Before cutting your plywood, adjust your saw blade to the right depth. If your blade is set too deep, you'll be dragging a lot of excess blade through the sheet. If you have your blade set too shallow, you run the risk of not cutting all the way through the sheet.<ref name="rf3"> http://www.familyhandyman.com/tools/circular-saws/how-to-cut-plywood/view-all</ref> |
| − | #* You want your saw to be about {{convert|.25|in|cm|1}} below the sheet. If you're cutting a sheet of plywood that is {{convert|.75|in|cm|1}} thick, set your blade to {{convert|1|in|cm|1}} deep.<ref | + | #* You want your saw to be about {{convert|.25|in|cm|1}} below the sheet. If you're cutting a sheet of plywood that is {{convert|.75|in|cm|1}} thick, set your blade to {{convert|1|in|cm|1}} deep.<ref name="rf1" /> |
| − | #Support the whole piece of wood. When cutting a sheet of plywood, it's important that you support the sheet on both sides of the cut.<ref | + | #Support the whole piece of wood. When cutting a sheet of plywood, it's important that you support the sheet on both sides of the cut.<ref name="rf1" /> |
| − | #* A few long 2x4s laid across two sawhorses will keep the sheet steady as you cut. Keep the 2x4s handy just for this task, as you'll be cutting into the tops of them with your circular saw.<ref | + | #* A few long 2x4s laid across two sawhorses will keep the sheet steady as you cut. Keep the 2x4s handy just for this task, as you'll be cutting into the tops of them with your circular saw.<ref name="rf1" /> |
| − | #* If you don't have access to 2x4s or sawhorses, you can use a piece of rigid foam insulation instead. Lay the foam on the ground, and lay the sheet of plywood on top. Make sure the wood doesn't slide around on top of the foam board.<ref | + | #* If you don't have access to 2x4s or sawhorses, you can use a piece of rigid foam insulation instead. Lay the foam on the ground, and lay the sheet of plywood on top. Make sure the wood doesn't slide around on top of the foam board.<ref name="rf1" /> |
| − | #* If you use the foam board method, you can crawl across the board as you cut, and you don't have to worry about the board snapping off at the end of the cut.<ref>http://www.familyhandyman.com/tools/circular-saws/how-to-cut-plywood/view-all</ref> | + | #* If you use the foam board method, you can crawl across the board as you cut, and you don't have to worry about the board snapping off at the end of the cut.<ref name="rf4">http://www.familyhandyman.com/tools/circular-saws/how-to-cut-plywood/view-all</ref> |
| − | #Cut with the good side down. When using a circular saw, place your plywood on the cutting surface with the good face down. The teeth of the blade enter the sheet from underneath, and exit at the top. When the teeth exit, they may cause some chipping. Placing the sheet with the good face down will ensure a smooth surface.<ref>http://www.woodmagazine.com/woodworking-tips/techniques/sawing-solutions/pointers-for-perfect-plywood-cuts/?catref=cat7580003&page=11</ref> | + | #Cut with the good side down. When using a circular saw, place your plywood on the cutting surface with the good face down. The teeth of the blade enter the sheet from underneath, and exit at the top. When the teeth exit, they may cause some chipping. Placing the sheet with the good face down will ensure a smooth surface.<ref name="rf5">http://www.woodmagazine.com/woodworking-tips/techniques/sawing-solutions/pointers-for-perfect-plywood-cuts/?catref=cat7580003&page=11</ref> |
| − | #Mark your cutting line. Use a straight edge to mark your line. Measure carefully and make sure you have the cutting line square with the edge of your plywood.<ref | + | #Mark your cutting line. Use a straight edge to mark your line. Measure carefully and make sure you have the cutting line square with the edge of your plywood.<ref name="rf3" /> |
| − | #* For a smoother cut, score your line. Use a utility knife to score your line before you cut. You may have to run your knife over the line a few times to get it to score completely.<ref | + | #* For a smoother cut, score your line. Use a utility knife to score your line before you cut. You may have to run your knife over the line a few times to get it to score completely.<ref name="rf4" /> |
#* A good rule to follow is "measure twice, cut once." If you cut the wood wrong, you can't do much to fix it other than start over with a new piece of wood. | #* A good rule to follow is "measure twice, cut once." If you cut the wood wrong, you can't do much to fix it other than start over with a new piece of wood. | ||
| − | #Use a guide to cut. Find a piece of plywood that still has its factory edge and attach it to your cutting surface using clamps.<ref | + | #Use a guide to cut. Find a piece of plywood that still has its factory edge and attach it to your cutting surface using clamps.<ref name="rf1" /> |
#* Take into consideration the width of the saw's base plate, or shoe. Adjust your guide so that the shoe fits firmly against the guide, and the blade is in line with your cut mark. | #* Take into consideration the width of the saw's base plate, or shoe. Adjust your guide so that the shoe fits firmly against the guide, and the blade is in line with your cut mark. | ||
| − | #* If you are planning on cutting a lot of plywood, you might consider investing in a saw guide that attaches to your circular saw. Look online or in your local hardware store to find one that suits your needs.<ref | + | #* If you are planning on cutting a lot of plywood, you might consider investing in a saw guide that attaches to your circular saw. Look online or in your local hardware store to find one that suits your needs.<ref name="rf1" /> |
| − | #Make your cut. Line your saw up with your guide, and make sure the blade is over your cut mark. Turn your saw on, and run the shoe of the saw along your guide. Take care to make your cut as straight as possible.<ref | + | #Make your cut. Line your saw up with your guide, and make sure the blade is over your cut mark. Turn your saw on, and run the shoe of the saw along your guide. Take care to make your cut as straight as possible.<ref name="rf1" /> |
#* Using a saw is dangerous. Wear safety goggles at all times, and keep your fingers clear of the blade. | #* Using a saw is dangerous. Wear safety goggles at all times, and keep your fingers clear of the blade. | ||
#* Watch out for the power cord as you cut. Keep your work area clean. | #* Watch out for the power cord as you cut. Keep your work area clean. | ||
=== Cutting Plywood with a Table Saw === | === Cutting Plywood with a Table Saw === | ||
| − | #Choose the right blade. To get the smoothest cut from your table saw, invest in a blade with a high tooth count, such as an 80 TPI plywood blade.<ref | + | #Choose the right blade. To get the smoothest cut from your table saw, invest in a blade with a high tooth count, such as an 80 TPI plywood blade.<ref name="rf2" /> |
| − | #* Most stock blades on table saws work well for rough cuts, but will not give you a clean edge.<ref | + | #* Most stock blades on table saws work well for rough cuts, but will not give you a clean edge.<ref name="rf2" /> |
#* Alternatively use a zero-clearance insert under the plywood. To make one of these, carefully set a piece of wood or plywood onto the working table saw, taking care not to have the wood slip or pull from your hands. Once the blade is all the way through (the blade needs to be quite high), clamp the insert down. You will be cutting on the insert, which does not allow the bottom layer of plywood to chip downward because of the low clearance between the blade and the insert. The insert is sacrificial and it's usually only sensible to make one when cutting large amounts of plywood. | #* Alternatively use a zero-clearance insert under the plywood. To make one of these, carefully set a piece of wood or plywood onto the working table saw, taking care not to have the wood slip or pull from your hands. Once the blade is all the way through (the blade needs to be quite high), clamp the insert down. You will be cutting on the insert, which does not allow the bottom layer of plywood to chip downward because of the low clearance between the blade and the insert. The insert is sacrificial and it's usually only sensible to make one when cutting large amounts of plywood. | ||
| − | #Raise the blade. Raising the blade changes the direction the teeth will enter the wood. When the blade is slightly raised, such that the teeth just barely cut through the surface, the teeth enter the cutting surface at an angle. If you raise the blade a little higher, you can get a perpendicular cut, which will make a smoother surface.<ref | + | #Raise the blade. Raising the blade changes the direction the teeth will enter the wood. When the blade is slightly raised, such that the teeth just barely cut through the surface, the teeth enter the cutting surface at an angle. If you raise the blade a little higher, you can get a perpendicular cut, which will make a smoother surface.<ref name="rf2" /> |
| − | #* Don't raise the blade more than {{convert|1|in|cm|1}} above the cutting surface. A raised blade may offer a smoother cut, but it also makes for a more dangerous cut. Exercise extreme caution when cutting with a raised blade.<ref | + | #* Don't raise the blade more than {{convert|1|in|cm|1}} above the cutting surface. A raised blade may offer a smoother cut, but it also makes for a more dangerous cut. Exercise extreme caution when cutting with a raised blade.<ref name="rf2" /> |
| − | #Use a zero-clearance insert. Your table saw may have a gap between the blade and the throat plate, where the blade sits in the table saw. A zero-clearance insert closes the gap and offers support to the sheet, making a smoother cut.<ref | + | #Use a zero-clearance insert. Your table saw may have a gap between the blade and the throat plate, where the blade sits in the table saw. A zero-clearance insert closes the gap and offers support to the sheet, making a smoother cut.<ref name="rf2" /> |
| − | #* You can purchase a zero-clearance throat plate online or at your local hardware store.<ref | + | #* You can purchase a zero-clearance throat plate online or at your local hardware store.<ref name="rf2" /> |
#* Alternatively make your own. First, carefully set a piece of wood or plywood onto the working table saw, taking care not to have the wood slip or pull away from your hands. Once the blade is all the way through (the blade needs to be quite high), clamp the insert down. You will be cutting on the insert, which does not allow the bottom layer of plywood to chip downward because of the low clearance between the blade and the insert. The insert is sacrificial and it's usually only sensible to make one when cutting large amounts of plywood. To make safe cuts, make sure that whatever you're cutting isnt at an angle or unsupported on the other side. | #* Alternatively make your own. First, carefully set a piece of wood or plywood onto the working table saw, taking care not to have the wood slip or pull away from your hands. Once the blade is all the way through (the blade needs to be quite high), clamp the insert down. You will be cutting on the insert, which does not allow the bottom layer of plywood to chip downward because of the low clearance between the blade and the insert. The insert is sacrificial and it's usually only sensible to make one when cutting large amounts of plywood. To make safe cuts, make sure that whatever you're cutting isnt at an angle or unsupported on the other side. | ||
| − | #Support the entire sheet. Large pieces of plywood can get heavy. When cutting them on a table saw, make sure you can keep it flat before beginning your cut. Stabilize the sheet on sawhorses, or ask a friend to help you hold it steady.<ref | + | #Support the entire sheet. Large pieces of plywood can get heavy. When cutting them on a table saw, make sure you can keep it flat before beginning your cut. Stabilize the sheet on sawhorses, or ask a friend to help you hold it steady.<ref name="rf2" /> |
| − | #* Having the entire sheet supported allows you to keep a steady feed rate, that is, the speed you run the wood through the saw.<ref | + | #* Having the entire sheet supported allows you to keep a steady feed rate, that is, the speed you run the wood through the saw.<ref name="rf2" /> |
| − | #* You can also use a circular saw to break down large sheets to more manageable sizes.<ref | + | #* You can also use a circular saw to break down large sheets to more manageable sizes.<ref name="rf2" /> |
| − | #Tape off your cut mark. Use a low-adhesion tape, such as painter's tape, on both faces of your sheet. This will help hold the wood fibers in place and keep the edges from splintering.<ref | + | #Tape off your cut mark. Use a low-adhesion tape, such as painter's tape, on both faces of your sheet. This will help hold the wood fibers in place and keep the edges from splintering.<ref name="rf2" /> |
| − | #* Once you have finished cutting, peel the tape off slowly to avoid any splintering.<ref | + | #* Once you have finished cutting, peel the tape off slowly to avoid any splintering.<ref name="rf2" /> |
| − | #Cut with the good face up. Lay your sheet on your table saw with the good face up. The teeth of the saw will enter the sheet from the top and exit from the underside of the sheet. Tear-outs, or splintering, will occur where the teeth exit, so keep the good face up. <ref | + | #Cut with the good face up. Lay your sheet on your table saw with the good face up. The teeth of the saw will enter the sheet from the top and exit from the underside of the sheet. Tear-outs, or splintering, will occur where the teeth exit, so keep the good face up. <ref name="rf5" /> |
| − | #Make the cut. Hold your sheet steady and keep it pressed firmly against the fence, the straight edge of your table saw. Use both hands to guide the sheet through the blade.<ref | + | #Make the cut. Hold your sheet steady and keep it pressed firmly against the fence, the straight edge of your table saw. Use both hands to guide the sheet through the blade.<ref name="rf5" /> |
| − | #* Use the hand that is closest to the blade to press the sheet forward, through the blade. Use the hand that is furthest from the blade to press the sheet towards the cutline.<ref | + | #* Use the hand that is closest to the blade to press the sheet forward, through the blade. Use the hand that is furthest from the blade to press the sheet towards the cutline.<ref name="rf5" /> |
| − | #* As you get close to the end of the cut, move your hands so that you have one hand on either side of the blade. Carefully push the rest of the sheet through the blade.<ref | + | #* As you get close to the end of the cut, move your hands so that you have one hand on either side of the blade. Carefully push the rest of the sheet through the blade.<ref name="rf5" /> |
#* Work carefully when using your table saw. Keep your hands away from the blade. | #* Work carefully when using your table saw. Keep your hands away from the blade. | ||
=== Making a Plunge Cut === | === Making a Plunge Cut === | ||
| − | #Make sure the sheet is stable. Lay your sheet of plywood on a few 2x4s suspended over two sawhorses. The entire sheet of plywood should be seated firmly on the work surface.<ref>http://ana-white.com/2015/03/tips-cutting-plywood-circular-saw</ref> | + | #Make sure the sheet is stable. Lay your sheet of plywood on a few 2x4s suspended over two sawhorses. The entire sheet of plywood should be seated firmly on the work surface.<ref name="rf6">http://ana-white.com/2015/03/tips-cutting-plywood-circular-saw</ref> |
| − | #* A plunge cut is a cut that does not start from a straight edge, but the center of a sheet of plywood. If you need to make an opening in the middle of a sheet of plywood, for example, you would need to make a plunge cut.<ref>http://www.familyhandyman.com/tools/miter-saws/how-to-make-perfect-cuts-with-circular-and-miter-saws/view-all</ref> | + | #* A plunge cut is a cut that does not start from a straight edge, but the center of a sheet of plywood. If you need to make an opening in the middle of a sheet of plywood, for example, you would need to make a plunge cut.<ref name="rf7">http://www.familyhandyman.com/tools/miter-saws/how-to-make-perfect-cuts-with-circular-and-miter-saws/view-all</ref> |
| − | #Set the blade depth. Lower the blade to about {{convert|.25|in|cm|1}} more than the thickness of your sheet. This will ensure the teeth of the blades just barely cut through the underside of the surface.<ref | + | #Set the blade depth. Lower the blade to about {{convert|.25|in|cm|1}} more than the thickness of your sheet. This will ensure the teeth of the blades just barely cut through the underside of the surface.<ref name="rf7" /> |
| − | #Stand to the side of the saw. There is a high risk of kick back, or the saw running back towards you, when making a plunge cut. Do not stand directly behind the saw when you make a plunge cut.<ref | + | #Stand to the side of the saw. There is a high risk of kick back, or the saw running back towards you, when making a plunge cut. Do not stand directly behind the saw when you make a plunge cut.<ref name="rf7" /> |
| − | #Position your saw for a plunge cut. Place the front edge of the shoe, or the base plate of the saw, against your sheet of plywood. Carefully lift up the blade guard, and line the blade up with your cut mark.<ref | + | #Position your saw for a plunge cut. Place the front edge of the shoe, or the base plate of the saw, against your sheet of plywood. Carefully lift up the blade guard, and line the blade up with your cut mark.<ref name="rf7" /> |
| − | #Keep the underside of the blade clear. You won't be able to see what is beneath the sheet as you make your plunge cut, so check before hand to make sure the space is clear.<ref | + | #Keep the underside of the blade clear. You won't be able to see what is beneath the sheet as you make your plunge cut, so check before hand to make sure the space is clear.<ref name="rf7" /> |
| − | #Lower the blade into the plywood. Turn the saw on and slowly lower the saw blade into the sheet. Hold the saw firmly to keep it from kicking back to you.<ref | + | #Lower the blade into the plywood. Turn the saw on and slowly lower the saw blade into the sheet. Hold the saw firmly to keep it from kicking back to you.<ref name="rf7" /> |
| − | #* Once the saw is completely lowered into the cut, and the saw bed is flush with the cutting surface, release the blade guard. Move the saw forward to finish the cut. Let the blade come to a complete stop before lifting the saw out of the sheet.<ref | + | #* Once the saw is completely lowered into the cut, and the saw bed is flush with the cutting surface, release the blade guard. Move the saw forward to finish the cut. Let the blade come to a complete stop before lifting the saw out of the sheet.<ref name="rf7" /> |
=== Cutting Plywood with a Hand Saw === | === Cutting Plywood with a Hand Saw === | ||
| − | #Buy a good saw. If you don't have access to power tools, you'll need to invest in a solid crosscut saw. Look at a saw's TPI, or teeth per inch. A saw with fewer teeth will cut faster, but you'll be left with a rough edge. A saw with a higher TPI will leave you with a smoother edge, but it will take some time to saw.<ref>http://www.hometips.com/diy-how-to/using-basic-tools.html</ref> | + | #Buy a good saw. If you don't have access to power tools, you'll need to invest in a solid crosscut saw. Look at a saw's TPI, or teeth per inch. A saw with fewer teeth will cut faster, but you'll be left with a rough edge. A saw with a higher TPI will leave you with a smoother edge, but it will take some time to saw.<ref name="rf8">http://www.hometips.com/diy-how-to/using-basic-tools.html</ref> |
| − | #* Make sure the handle is comfortable when you grip it, and look down the back of the saw blade to make sure it is straight. The tip of the saw should be flexible. When you bend it, it should snap back to the center.<ref | + | #* Make sure the handle is comfortable when you grip it, and look down the back of the saw blade to make sure it is straight. The tip of the saw should be flexible. When you bend it, it should snap back to the center.<ref name="rf8" /> |
#Measure your cut. Anytime you are working with wood, make sure to measure your cut. Once the wood has been cut, there is no turning back. Double check your measurements before cutting. | #Measure your cut. Anytime you are working with wood, make sure to measure your cut. Once the wood has been cut, there is no turning back. Double check your measurements before cutting. | ||
| − | #Notch the wood. Start on the edge of the board, and hold the saw blade upright. Draw the saw up a few times to get a notch in the edge of the board.<ref | + | #Notch the wood. Start on the edge of the board, and hold the saw blade upright. Draw the saw up a few times to get a notch in the edge of the board.<ref name="rf8" /> |
| − | #* You can use your thumb knuckle to guide the blade, but be careful.<ref | + | #* You can use your thumb knuckle to guide the blade, but be careful.<ref name="rf8" /> |
| − | #Start the cut. When you've made a solid notch in the edge, bring the saw to about 45-30 degrees. Work carefully and use smooth, full strokes to cut plywood.<ref | + | #Start the cut. When you've made a solid notch in the edge, bring the saw to about 45-30 degrees. Work carefully and use smooth, full strokes to cut plywood.<ref name="rf8" /> |
| − | #* Keep your forearm and shoulder in line with the blade to ensure a straight cut.<ref | + | #* Keep your forearm and shoulder in line with the blade to ensure a straight cut.<ref name="rf8" /> |
| − | #* If you notice the blade running off track, give the handle a little twist to set it right.<ref | + | #* If you notice the blade running off track, give the handle a little twist to set it right.<ref name="rf8" /> |
| − | #Brace the cutoff end to avoid splinters. When you get towards the end of your cut, use your free hand to hold the cutoff end. Turn the saw upright and use short vertical strokes to finish the cut.<ref | + | #Brace the cutoff end to avoid splinters. When you get towards the end of your cut, use your free hand to hold the cutoff end. Turn the saw upright and use short vertical strokes to finish the cut.<ref name="rf8" /> |
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== Tips == | == Tips == | ||
