You can find blades labeled for plywood or “finished cuts,” but make sure to check the tooth count. [2] X Research source Blades come in various sizes, so be sure you get one that will fit your circular saw. [3] X Research source If you stick with the blade that came with your saw, you’ll likely end up with splintered ends, also known as tear-outs. [4] X Research source
You want your saw to be about . 25 inches (0. 6 cm) below the sheet. If you’re cutting a sheet of plywood that is . 75 inches (1. 9 cm) thick, set your blade to 1 inch (2. 5 cm) deep. [6] X Research source
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. [8] X Research source 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. [9] X Research source 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. [10] X Research source
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. [13] X Research source 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.
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. [15] X Research source
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.
Most stock blades on table saws work well for rough cuts, but will not give you a clean edge. [18] X Research source 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.
Don’t raise the blade more than 1 inch (2. 5 cm) 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. [20] X Research source
You can purchase a zero-clearance throat plate online or at your local hardware store. [22] X Research source 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 isn’t at an angle or unsupported on the other side.
Having the entire sheet supported allows you to keep a steady feed rate, that is, the speed you run the wood through the saw. [24] X Research source You can also use a circular saw to break down large sheets to more manageable sizes. [25] X Research source
Once you have finished cutting, peel the tape off slowly to avoid any splintering. [27] X Research source
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. [30] X Research source 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. [31] X Research source Work carefully when using your table saw. Keep your hands away from the blade.
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. [33] X Research source
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. [39] X Research source
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. [41] X Research source
You can use your thumb knuckle to guide the blade, but be careful. [43] X Research source
Keep your forearm and shoulder in line with the blade to ensure a straight cut. [45] X Research source If you notice the blade running off track, give the handle a little twist to set it right. [46] X Research source
