Methods of Cutting Plywood

There are any number of ways to get a 4' by 8' sheets cut into smaller pieces. Some methods are easier than others, but may not meet the standards of accuracy required.

Probably the simplest way to cut sheet goods, whether it be plywood, Melamine, Particle Board, or M.D.F., is to have it cut at the point of purchase. If you're buying your materials at a big box store, they will cut it for you. Generally, the first cut is free, and additional cuts are one dollar. While that's very convenient, there is a down side to this.

First, they won't guarantee any real accuracy in the measuring of the pieces. And the are often pretty rough and ragged cuts. Certainly, not furniture quality cuts by any means. The way around this, is to cut everything oversized, and trim them to the final size later.

This also means you need to have a cut list prepared prior to buying your materials. This is just a small nuisance, as you'll have to figure it out sooner or later anyway.

Another method is what most contractors do at a job site, and that's using a chalk line to mark the sheet, and a circular saw to cut it. This is a pretty quick way of doing it, but unless you do it a lot, the resulting cut may be a little wavy.

There are a number of guide systems available, ranging from a shop made plywood edge, which you clamp to the sheet, to a Festool track and saw combination. The festool system is expensive, but worth every penny. It very easy to use, and gives cabinet quality cuts, with no splintering.

There is a number of other steel and aluminum track systems available, but I have not seen any that are as good, or easy to use, as the Festool.

Next would be a table saw. The larger the saw table, the easier it is to cut sheet goods. Stands to reason, as the table is helping to hold the weight of the sheet, which in some extreme cases can be eighty pounds or more.

The difficulty in using a table saw is when first starting the cut, since placing the sheet onto the saw is not the most graceful thing to do, and is often where most back strains occur while cutting these bulky sheets. There are a couple accessories, designed with this problem in mind.

The first would be the roller stand. It is the least costly option, but also the least effective. Knocking it over is common, as is moving it just enough so the roller is no longer perpendicular to the rip fence.

This actually forces the sheet to pull away from the fence, resulting in a poor cut, and burned edges. They do make roller stands with transfer balls, which eliminates that problem.

Relatively new to the market is the Ezee-Feed infeed system. This is a steel frame, with fold down legs, so it takes up very little space when not in use.

It has multi directional transfer balls, so moving the sheets in any direction is simple. It attaches, or mounts to the saw in seconds, so it can't be knocked over.

And it has a side roller to allow you to roll the sheet onto the table, with very little risk of back strain.

Once you have the sheet on the infeed table, using it to get perfect cuts is simple. You are not holding any weight what-so-ever. Zero, zip, nada!

You can stand at the edge of the saw, instead of the end of the sheet, so you have a perfect view of the cut, at all times. You are not holding the sheet and walking forward. This cutting technique will not result in a perfect cut, as it is simply not possible.

Using an ezee-feed table, you feed the sheet, regardless of it's weight, with one hand, and hold it tight to the fence with the other hand. You can rip a strip off the edge of the sheet, less than 1/16 of an inch thick, without burns or blade marks. Strips thin enough to tie in a knot!

The danger of kick back is reduced significantly, since you are not moving while feeding the sheet. The speed at which you can make cuts is doubled, due to the above mentioned benefits.

And the quality of cut is perfect, every time, without exception. The only down side to the infeed table is the fact it won't help you on the outfeed side of the saw.

Fortunately, we make an out feed system too! Offering all the same advantages as the in feed table.