How To Cut Plywood With Table Saw: Achieving Clean Cuts

Can I cut plywood with a table saw? Yes, you can cut plywood with a table saw. However, achieving clean, accurate cuts requires using the right techniques, the proper blade, and understanding how to manage this versatile but sometimes challenging material. This guide will give you all the information you need to master plywood cutting techniques with a table saw.

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Selecting the Right Blade: The Key to Clean Plywood Cuts

The table saw plywood blade is the most important factor in getting clean cuts. Plywood, being a composite material made of thin wood veneers glued together, is prone to splintering and tearout. A blade designed for plywood helps minimize these issues.

Tooth Count and Grind Explained

• High Tooth Count: Blades with a higher tooth count (60-80 teeth) are ideal for plywood. More teeth create a finer cut, reducing tearout on both the top and bottom surfaces of the plywood.
• Tooth Grind: The tooth grind also matters. An Alternate Top Bevel (ATB) grind is a common choice. It alternates the bevel of each tooth to the left and right, scoring the wood fibers before the next tooth cuts. This creates a cleaner edge.

Best Blade for Plywood Recommendations

Here are some recommended blade types for achieving clean cuts in plywood:

• Dedicated Plywood Blades: These blades are specifically designed for plywood and other veneered materials. They typically have a high tooth count (80+) and a specialized tooth grind for minimal tearout.
• Fine Finish Blades: These blades are versatile and can be used for plywood as well as other fine woodworking projects. Look for blades with 60-80 teeth and an ATB grind.
• Combination Blades: While not ideal, a high-quality combination blade with a high tooth count can work in a pinch. However, you may still experience some tearout, especially on thicker plywood.

Blade Comparison Table

Blade Type	Tooth Count	Grind	Pros	Cons	Best For
Plywood Blade	80+	ATB	Minimal tearout, cleanest cuts	Can be more expensive, may not be ideal for thicker hardwoods	Fine plywood, veneered materials
Fine Finish Blade	60-80	ATB	Good balance of clean cuts and cutting speed	May produce slightly more tearout than a dedicated plywood blade	General woodworking, plywood, hardwood
Combination Blade	40-50	ATB/FTG	Versatile, can handle a variety of materials	Increased tearout compared to plywood-specific blades	Rough cuts, construction lumber, some plywood

Setting Up Your Table Saw for Plywood

Proper setup is crucial for accurate and safe plywood cutting table saw.

Ensuring Accuracy with the Fence

• Checking for Square: Make sure your table saw fence plywood is perfectly square to the blade. Use a reliable square to check this. If it’s not square, adjust the fence until it is.
• Fence Lock-Down: Ensure the fence is securely locked down before making any cuts. A loose fence can lead to inaccurate cuts and potential kickback.
• Micro-Adjustments: If your fence has a micro-adjustment feature, use it to fine-tune the fence position for precise cuts.

Blade Height Adjustment

• Ideal Height: The ideal blade height is generally just high enough so the teeth protrude slightly above the plywood’s surface (about 1/4 inch). Too high, and you risk increased tearout and potential kickback. Too low, and the blade will struggle to cut efficiently, leading to a rougher cut.
• Testing: Before cutting your project piece, test the blade height on a scrap piece of plywood to ensure a clean cut. Adjust as needed.

Using a Zero Clearance Insert

• What it is: A zero clearance insert fills the gap around the blade on the table saw. This provides support to the wood fibers close to the blade, drastically preventing tearout plywood.
• Why Use It: A standard throat plate has a wider opening around the blade. This allows the wood fibers to flex and tear as the blade passes through. A zero-clearance insert minimizes this flexing.
• Making Your Own: You can buy zero clearance inserts or make your own by cutting a blank insert to fit your saw and then raising the blade through it to create a perfectly sized opening.

Plywood Cutting Techniques

Employing the correct plywood cutting techniques is critical for safe and precise results.

Ripping Plywood Table Saw

Ripping plywood table saw refers to cutting plywood along the length of the grain (or what would be the grain in solid wood).

• Supporting the Plywood: When ripping long pieces of plywood, use outfeed support (like a roller stand) to prevent the plywood from sagging. Sagging can cause the cut to bind and potentially kick back.
• Consistent Feed Rate: Maintain a steady feed rate. Pushing too fast can lead to tearout, while pushing too slow can cause burning.
• Push Sticks: Always use push sticks when ripping narrower pieces of plywood. Keep your hands away from the blade.

Crosscutting Plywood Table Saw

Crosscutting plywood table saw means cutting across the width of the plywood, perpendicular to the grain.

• Miter Gauge: For accurate crosscuts, use a miter gauge. Ensure the miter gauge is set to the correct angle and is sliding smoothly in its slot.
• Sled: Consider building or purchasing a crosscut sled for larger plywood sheets. A sled provides more support and control, allowing for safer and more accurate cuts.
• Clamping: When crosscutting smaller pieces, use clamps to secure the plywood to the miter gauge or sled.

Cutting Large Plywood Sheets

Cutting large plywood sheets presents a unique set of challenges.

• Support is Key: As mentioned earlier, support is crucial. Use outfeed tables, roller stands, and even sawhorses to support the entire sheet of plywood.
• Helper: If possible, have a helper assist you in managing the weight and size of the plywood sheet.
• Breaking Down the Sheet: Consider breaking down the large sheet into smaller, more manageable pieces before cutting your final dimensions. This makes the process safer and easier.

Achieving Accurate Plywood Cuts

• Measuring Precisely: Always measure your plywood carefully before cutting. Use a precise measuring tool like a steel ruler or a digital caliper.
• Marking Accurately: Use a sharp pencil or marking knife to mark your cut lines clearly and accurately.
• Cutting on the Line: Align the blade with the waste side of the line. This ensures that your final piece is the correct size.
• Test Cuts: Always make a test cut on a scrap piece of plywood to verify your measurements and fence settings.

Preventing Tearout Plywood: Advanced Techniques

Beyond choosing the right blade and setting up your saw properly, here are some advanced techniques for minimizing tearout.

Scoring the Cut Line

• How it Works: Before making the final cut, score the cut line with a utility knife or a scoring blade. This helps sever the wood fibers before the saw blade reaches them, reducing tearout.
• Scoring Blade: Some table saws have a scoring blade that runs ahead of the main blade. This is an excellent option for eliminating tearout, especially when working with expensive or delicate veneers.

Using Painter’s Tape

• Applying the Tape: Apply painter’s tape along the cut line on both the top and bottom surfaces of the plywood.
• Cutting Through the Tape: Cut through the tape with the saw blade. The tape helps hold the wood fibers together, preventing them from splintering.

Climb Cutting (Use with Extreme Caution!)

• What it is: Climb cutting involves feeding the plywood into the blade in the opposite direction of normal cutting. This technique can produce a very clean cut, but it is extremely dangerous.
• Why It’s Risky: Climb cutting can easily cause kickback. The blade can grab the plywood and throw it back at you with considerable force.
• When to Use (If Ever): Climb cutting should only be attempted by experienced woodworkers who fully understand the risks and have taken all necessary safety precautions. It is generally not recommended.

Safe Plywood Cutting Table Saw: Prioritizing Safety

Safety is paramount when using a table saw.

Essential Safety Gear

• Eye Protection: Always wear safety glasses or a face shield to protect your eyes from flying debris.
• Hearing Protection: Table saws are loud. Wear earplugs or earmuffs to protect your hearing.
• Dust Mask: Cutting plywood creates a lot of dust. Wear a dust mask or respirator to protect your lungs.

Safe Operating Practices

• Stay Focused: Pay attention to what you’re doing. Don’t get distracted.
• Keep Your Hands Away: Never reach over the blade. Use push sticks or push blocks to guide the plywood through the saw.
• Maintain a Firm Grip: Hold the plywood firmly against the fence and the table.
• Be Aware of Kickback: Kickback is a dangerous phenomenon where the blade grabs the wood and throws it back towards the operator. Be aware of the signs of kickback (binding, stalling) and take steps to prevent it.
• Don’t Force It: If the saw is struggling to cut, don’t force it. Stop, check the blade, and make sure everything is properly aligned.
• Disconnect Power When Adjusting: Always disconnect the power cord before making any adjustments to the saw or changing the blade.

Troubleshooting Common Problems

Even with the best techniques, you may encounter problems when cutting plywood. Here are some common issues and how to fix them.

• Tearout: This is the most common problem. Try using a plywood blade, a zero clearance insert, scoring the cut line, or applying painter’s tape.
• Burning: Burning is caused by the blade overheating. This can be due to a dull blade, a slow feed rate, or improper blade height. Try using a sharp blade, increasing the feed rate, or adjusting the blade height.
• Inaccurate Cuts: Inaccurate cuts can be caused by a loose fence, an improperly set miter gauge, or inaccurate measurements. Check your fence and miter gauge for squareness and accuracy, and double-check your measurements.
• Kickback: Kickback is a dangerous problem that can be caused by binding, pinching, or pushing the wood too quickly. Use feather boards, outfeed support, and always keep your hands away from the blade. If kickback occurs, immediately turn off the saw and assess the situation before proceeding.

FAQ: Plywood Cutting on a Table Saw

Q: What is the best type of blade for cutting plywood on a table saw?
A: The best blade for plywood is a dedicated plywood blade with a high tooth count (80+) and an Alternate Top Bevel (ATB) grind. Fine finish blades with 60-80 teeth are also a good option.

Q: Can I use a regular combination blade to cut plywood?
A: While you can use a combination blade, it may result in more tearout than a plywood-specific blade. If you use a combination blade, make sure it has a high tooth count.

Q: How can I prevent tearout when cutting plywood?
A: To prevent tearout, use a plywood blade, a zero clearance insert, score the cut line with a utility knife, and apply painter’s tape to the cut line.

Q: Is it safe to cut large sheets of plywood on a table saw?
A: Yes, but it requires careful setup and technique. Use plenty of support (outfeed tables, roller stands), and if possible, get a helper to assist you. Consider breaking down the sheet into smaller pieces first.

Q: How high should I set the blade when cutting plywood?
A: The blade should be set high enough so that the teeth protrude slightly above the surface of the plywood (about 1/4 inch).

Q: What should I do if I experience kickback?
A: If kickback occurs, immediately turn off the saw and assess the situation before proceeding. Ensure that the wood is not binding or pinching the blade, and that you are using proper technique and safety devices (feather boards, push sticks).

By following these guidelines and prioritizing safety, you can achieve clean, accurate, and professional-looking plywood cuts with your table saw. Good luck!