I'm working on a project to build a rack out of plywood for my clamps, using 3/4" plywood. I plan to drill 1" holes about 6" in from the edge and then cut out the area around those holes, resulting in a U-shape along the edge of the board. I'm considering using a crosscut sled on my table saw for this, but I'm a bit uneasy about handling small offcuts that might be produced. I know that if the offcut doesn't reach the back of the blade, it shouldn't pose a risk of being thrown back. However, I'm all about safety and would love some suggestions. Other methods I'm considering include using a jigsaw then cleaning it up on the table saw, making a router template or just cutting with a jigsaw and leaving it as is. There will be quite a few of these cuts to make, so I really want to find the safest and most efficient approach. What would you all recommend?
6 Answers
If you're worried about the small offcut flying off when you make that last cut, why not cut nearly all the way through to the hole, leaving it connected, and then finish it with a hand saw? That way, you have more control over the small piece as you cut!
The second option you mentioned, using a router template after a rough cut with a jigsaw, is probably your best bet. It gives you more control and cleaner edges without risking too much on those small offcuts. Just make sure to take it slow!
It's hard to imagine the offcut you're worried about, but you can work with really thin ones, as thin as 1/8" or less, without much risk. If you're using a sled, the offcut will stay in place even better since it rides along with it, so it should be a lot safer!
From what I understand about table saws, kickback mostly happens when the offcut gets pinched between the blade and the fence. If you're careful and not pushing the small pieces against the fence, they shouldn't just fly out of nowhere. But it'd be great to get a confirmation from someone with more experience!
If you're cutting a small piece, like a 3" wide offcut, just use a push stick to feed it through safely. Just keep in mind that if the gap between the blade and fence is less than an inch, things can get tricky; this is where a device like a Grripper can really help out!
Yeah, I'd agree with that technique—definitely less risk and more manageable!
That makes sense! I guess using the sled would be more reassuring for the offcuts.