I'm a newbie in woodworking tackling my first major project, which involves constructing a large wooden structure with built-in screens and electronics. The whole setup will measure about 320 cm x 220 cm x 16 cm (126 in x 87 in x 6.3 in) and is made from high-quality birch plywood, using both 12 mm (½ in) and 18 mm (¾ in) thicknesses. I need to position three large plywood sheets, each approximately 220 cm x 106 cm (87 in x 42 in), flush against each other at the front. The challenge is that I'm on-site and limited to the tools available, which include a large sliding table saw with a fence that isn't perfectly square. Fixing the saw is time-consuming, and I don't have a track saw either, but there's a saw guide usually meant for routers that's half the length needed for a single cut. Should I adapt my design to use smaller pieces or is there a good way to cut these large sheets straight with what I have?
3 Answers
If you can, make a new straight edge for the length you need. You could also buy an edge guide for your circular saw; that could work fantastic! It's odd that a shop with a sliding table saw wouldn't have someone able to straighten the fence—bad tools lead to bad cuts!
You could totally use the top sheet as a straight edge and clamp it down to the sheet below. Just grab your circular saw and cut along it—easy peasy! It'll help keep everything nice and straight, trust me.
I'd recommend getting a full-length straight edge, like an aluminum one, or just using a known straight cut on another piece of plywood. Just ensure you apply pressure evenly when cutting so the plywood doesn't bow. You could also shim the fence on that sliding table saw to get a square cut. It might take some time, but it could save you the hassle of cutting by hand.
Exactly! If the fence is off, adjusting it would definitely be worth the time. Good fences make good cuts!
Right? A good fence is half the battle with those tools. Just makes everything more frustrating.