Cutting 4x8 sheets

ferrari99 · Jan 21, 2016

I make feed bins and sell them (here's a video for interests sake https://www.youtube.com/watch?v=vsbhh21kvQM&feature=youtu.be)
The root of the problem is that plywood comes in 4x8 sheets (or 1.2x2.4 as we call them) obviously I have to cut them and that's the problem. How to cut ply repeatably and efficiently.
What would you suggest? I am currently using a small table saw with the fence but it takes three people to handle a sheet and it's hard to get a perfect cut.
My idea is to build a table with a fence and a circular saw on ball bearings. Like pictured below.

You can see the fence at the back and the carriage where the saw would sit on the right. The red things are clamps.
What do you think ideas? suggestion?
Thanks in advance,
ferrari99

Gunny · Jan 21, 2016

I cut my plywood by laying it on a sawhorse table, with battens spaced appropriately for the cuts to be made, then use something on this line:

Two Essential Saw Cutting Guides | The Family Handyman

basically made from scrap pieces of mdf/plywood, then a couple of good clamps. I made my guide so that the edge is exactly 12" from the cut, so I just add 12" to what needs to be cut, clamp the guide down and I'm good to go

Piston · Jan 21, 2016

I've always used a 6' level and two clamps to secure it to the plywood, then use it as a guide. I measured the distance from the center of the saw blade's width, to the edge of the skill saws aluminum base, then subtract that from whatever measurement I want (for example, 4') I lay out the line on the plywood and butt the level to the line, then double check, and cut. I get a very straight cut this way, but if doing it in mass production mode I would use a saw cutting guide, but I like your idea of the ball bearings.

smstonypoint · Jan 21, 2016

If I was cutting plywood sheets on a regular basis I would buy a track saw like Makita SP6000J1 6-1/2-Inch Plunge Circular Saw with Guide Rail - Power Circular Saws - Amazon.com or a panel saw like FREE SHIPPING — Milwaukee Panel Saw — 8 1/4in. Blade Size, Model# N6480-20 | Panel Saws| Northern Tool + Equipment.

Steve

kidr · Jan 21, 2016

I buy at Lowes and have them cut it up for free.

mark02tj · Jan 21, 2016

They have something like this at Home Depot and Lowes. Works good for cross-cuts. If you want to rip, you turn the saw 90 degrees and push the plywood through.

But, my first thought was what Steve linked to above. From what I understand about the track saws, you can lay the track right on the cut line and it cuts flush to the track. No measuring to compensate for how far the edge of the base plate of the saw is from the blade.

TheSpoon · Jan 21, 2016

You can make a rip cut jig easy enough. 1 sheet of ply (or hardboard is usually a better option) and you're all set.

Here's just one example.
Free Circular Saw Cutting Guide Plan - Free Panel Saw Plans

SimS · Jan 21, 2016

x2 on the panel saw. If you are in a "production" mode the panel saw will allow you to cut multiple sheets at the same time. Also no clamps, no bending over wide sheets to push the saw, etc.

SimS

Egon · Jan 21, 2016

Track saw.

[video]https://www.google.ca/search?q=tracksaw&client=safari&hl=en-ca&prmd=vin&source=lnms&tbm=isch&sa=X&ved=0ahUKEwir9MqwgLvKAhUGv4MKHfIYCMIQ_AUICCgC#imgr c=x3qTpjQFObxYZM%3A[/video]

tow653 · Jan 21, 2016

Festool makes a good track saw.

TheSpoon · Jan 21, 2016

tow653 said:
Festool makes a good track saw.

They better for the price of it.

Sawyer Rob · Jan 21, 2016

Track saw is the bomb for cutting down sheets of plywood...

Buy a good brand, NOT some Chinese copy though!

SR

MMagis · Jan 21, 2016

Guess it depends on how many you make and how much you want to spend. A good panel saw would certainly be the "best" way. This is just one example, cost varies quite a bit.
Safety Speed Cut Panel Pro 2 Saw PRO2K - Rockler Woodworking Tools

gsganzer · Jan 21, 2016

Look for a used panel saw. It makes cutting large sheets a 1 man operation and is much safer.

I bought a used Dewalt panel saw for $400

Milwaukee panel saw

Or use this idea and make a version of your own, Homemade panel saw

EddieWalker · Jan 21, 2016

Are you cutting plywood every day, once a week or just a few times a month? I tend to cut plywood several times a year and can go months at a time without having to cut it. Depending on what I'm doing, most of the time I just lay it across the sides of my truck bed and cut it with my cordless circular saw. If I'm building a cabinet or something that needs more accuracy, I use my portable Bosch table saw with 5 rollers set up around it to support the sheet of plywood as I'm cutting it. Once I'm set up, I can do this by myself quickly and easily. When I finally build my big workshop, I'll probably build a table to go around my table saw to support the plywood and double as another counter to work on. I've always wanted a panel saw, I think that would be the best tool for the job, but I've never actually used one and don't want to spend the money on getting one. Can you rip strips of plywood an inch wide, 8 feet long on a panel saw? What about a track saw?

bigtiller · Jan 21, 2016

Gunny said:
Two Essential Saw Cutting Guides | The Family Handyman

TheSpoon said:
Free Circular Saw Cutting Guide Plan - Free Panel Saw Plans

Gunny and Spoon are spot on, for an economical method to cut large sheets of plywood. I made one out of scraps that is only 6' long and i get by with it but an 8' one would be better. My 6' one workes best for cutting plywood on the 4' side.

bamboozled · Jan 21, 2016

I have a Dewalt track saw. Works pretty good and less expensive than the Festool.

ferrari99 · Jan 21, 2016

Thanks for all your replies. I am looking for something more efficient then a circular saw a guide. I've considered a track saw but it's not much better. I want something that I don't have to measure every cut. I like the idea of a panel saw and that's basically what I would like to build. Any thoughts on my design?
Here is a pretty nice homemade one. I only need to be able to crosscut not rip though. I would also make mine steel frame. And mine would be running on proper ball bearings. DIY panel saw - 2ManyProjects

GPintheMitten · Jan 21, 2016

Your thread got me looking around the Internet for home made panel saws. I saw that one and a few others that looked pretty good. There was also a commercial made kit with all the hardware including a polycarbonate mount for the saw.
https://youtu.be/tVubVWzgm_s

That one starts at $259 US, You supply the saw and wood to construct the frame.