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ShaneB · 06-11-2006, 07:48 PM

Can anyone help provide some tips for getting accurate square plywood panels cut for cabinet sides, backs, etc. It seems to take me forever to get perfectly square panels cut from a 4x8' sheet of plywood. I have been rough cutting my pieces with a circular saw and then using straight edge to get them trimmed square. Next, I have been using the first panel as a template and using a flush trim bit with my router to create a duplicate. There has got to be an easier way. My table saw is a relatively small 10" Craftsman with not a lot of table space.

Any help is much appreciated. Thanks.

Shane

**bobj3** · 06-11-2006, 08:58 PM

Shane
You can make a Panel Saw but they are not cheap to make or buy.
http://froogle.google.com/froogle?q=...Search+Froogle

It's always been hard for one man to take on a 4' x 8' plywood,but the next best thing is to use a jig like the snapshot below ▼
http://www.routerforums.com/attachme...achmentid=2505
http://www.routerforums.com/attachme...achmentid=2506
http://www.routerforums.com/attachme...achmentid=2507
just clamp it in place and cut the panels and they will come out SQ. and true every time.
I should note *** The saw drops in the slot on the clamp so it can't move off the cut.( It will cut true)

Once you get the 4 x 8 plywood down in size it's can be put it on the table saw to make your rip cuts or use your panel cutting jig on the table saw.
(panel cutting jigs are quick and easy to make )
They use the slot in the table saw to keep the panel true when you cut it.

Bj

**Mike** · 06-12-2006, 09:34 AM

Another way is to purchase plans and build a table surround for your saw. This is basicly a larger stand which supports your saw and material. I believe you will find plans at Shopnotes.com You can also purchase a ready made stand from the Rousseau company. Either way you increase the capacity of your small table saw. To get the best results build a saw sled; this is a panel with a guide strip on the bottom which follows your miter slot. You most likely have seen this panel cutting sled on the NYW. Plans are available from Popular Woodworking.

ShaneB · 06-12-2006, 07:47 PM

I have thought about making a panel sled for my table saw, however, I have a craftsman that has awful miter slots. They are almost like a "T slot" and have small notches every couple of inches to keep the miter slides from lifting. It makes retro-fitting other miter slide jigs difficult. I am thinking of cutting the notches off if the miter slot is the same size as standard slots.

Thanks for the info guys.

ShaneB · 06-12-2006, 07:53 PM

Bob,

I can't quite figue out the jig in your photos. It appears to be just a straight edge to me. How does the saw portion of the jig ride along the straight edge?

Shane

**bobj3** · 06-12-2006, 08:36 PM

Shane
It's a L shape alum stock, it hooks in the channel of the quick clamp.
You don't need to hold it down just a light push on the saw and it will track true.
The 1/16" carb.bit saw blade will give you a clean cut with almost no rip outs on plywood.
-----------------
Look real close at the black bracket in the snapshot
http://www.routerforums.com/attachme...achmentid=2505
part of the ( L ) bracket is deep inside the slot,about 1/32" from the bottom of the slot I used the MDF stock to set the depth of the lock in part of the L.

Just a side NOTE***I made one for the router also and it works great for Dado's and anything that you want to use it on.
http://www.routerforums.com/table-mounted-routing/2634-issues-cutting-dovetail-dados-table-router.html

Just a note about the Craftsman Table Saw.
When you make a Panel cutting jig you need to make a T-slot that will fit the saw table, I have the same saw and I will post a snapshot if you want to take a look at it.
It's two part T-Slot fixture and it works great in the saw table.

Just ask and I will post a snapshot.

Bj

**bobj3** · 06-13-2006, 01:54 AM

Shane

Here are some snapshots how to make a panel cutting jig for the Craftsman table saw.

Hope they help you

Bj

**Mike** · 06-13-2006, 07:25 AM

You could also make the guide strip from a piece of hardwood by cutting a strip 1/2 x 5/8" and removing 1/16x 1/4" deep from each side on your router table. UHMW is the ideal material since it is "self lubricating" but HDPE would work well too.

ShaneB · 06-13-2006, 08:26 AM

You're the Best Bob! I can't believe that you have the same saw. I have been scratching my head over this for months. Thank you so much. I plan to make one this weekend.

**bobj3** · 06-13-2006, 10:34 AM

You're Welcome Shane

Post a picture or two after you make it this weekend.

NoTE ***Besure to put your plywood blade in the saw b/4 you start.
Plus use your zero insert plate in the saw top.
If you don't have one just remove the one from the saw and use the plastic you have left over to make 2 1/2' X 10" long insert,you will need a rubber gromett under the back side on the insert and a 3/16" steel washer under the front one.(the grommet will compress down and hold the plate in place)
You will also need to put a rabbit on 3 sides on the insert 1/4" wide 3/16" deep ,this will let the insert set right in the hole.(on the alum.tabs )
Place it in the saw table screw it down and move the blade up ( with care) now you have one.
Make two or three at the same time,they are nice to have on hand.
The 1st one I made (in the snapshot ) told me the saw blade was off a bit so I did fix that now the blade cuts true,that's hard to see in the Fac.insert because it's so wide of a slot.

60/80 tooth Blade
This will cut the plastic a bit cleaner and when you cut the panel sled
it will be just right when you cut the plywood for the panels.
Then it's set for dead on cuts and you can add a stop block on the right end side then you can cut them all the same size.

In the snapshot you will see my combo blade in place don't use yours,see notes.

One more NOTE about the table saw, I didn't care for the chip bag under the table so I took it off and put in a plastic flower pot ,hahahahaha I know,you know that it has a plastic part to hook the bag on to under the table saw, I found a plastic flower pot that was just the right size,for two bucks and some black paint and 4 screws, it looks like a fac.part,I put in a hole to hold the app. and the vac hose now all the chips get put into the vac system bag.
see snapshots how to put one in your Craftsman Saw.

Have a good one
Bj

06-11-2006, 07:48 PM	#1
ShaneB Registered User Dedicated Member Join Date: Sep 2005 Posts: 36 View ShaneB's Gallery	Report This Post! Squaring plywood panels Can anyone help provide some tips for getting accurate square plywood panels cut for cabinet sides, backs, etc. It seems to take me forever to get perfectly square panels cut from a 4x8' sheet of plywood. I have been rough cutting my pieces with a circular saw and then using straight edge to get them trimmed square. Next, I have been using the first panel as a template and using a flush trim bit with my router to create a duplicate. There has got to be an easier way. My table saw is a relatively small 10" Craftsman with not a lot of table space. Any help is much appreciated. Thanks. Shane
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06-11-2006, 08:58 PM	#2
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,256 View bobj3's Gallery	Report This Post! Shane You can make a Panel Saw but they are not cheap to make or buy. http://froogle.google.com/froogle?q=...Search+Froogle It's always been hard for one man to take on a 4' x 8' plywood,but the next best thing is to use a jig like the snapshot below ▼ http://www.routerforums.com/attachme...achmentid=2505 http://www.routerforums.com/attachme...achmentid=2506 http://www.routerforums.com/attachme...achmentid=2507 just clamp it in place and cut the panels and they will come out SQ. and true every time. I should note *** The saw drops in the slot on the clamp so it can't move off the cut.( It will cut true) Once you get the 4 x 8 plywood down in size it's can be put it on the table saw to make your rip cuts or use your panel cutting jig on the table saw. (panel cutting jigs are quick and easy to make ) They use the slot in the table saw to keep the panel true when you cut it. Bj __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J. Last edited by bobj3; 06-11-2006 at 09:01 PM.
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06-12-2006, 09:34 AM	#3
Mike Senior Moderator Supreme Forum King Join Date: Nov 2004 Location: Detroit, Michigan USA Posts: 3,372 View Mike's Gallery	Report This Post! Another way is to purchase plans and build a table surround for your saw. This is basicly a larger stand which supports your saw and material. I believe you will find plans at Shopnotes.com You can also purchase a ready made stand from the Rousseau company. Either way you increase the capacity of your small table saw. To get the best results build a saw sled; this is a panel with a guide strip on the bottom which follows your miter slot. You most likely have seen this panel cutting sled on the NYW. Plans are available from Popular Woodworking. __________________ Mike Please edit your profile with a name and location so we can better assist you.
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06-12-2006, 07:47 PM	#4
ShaneB Registered User Dedicated Member Join Date: Sep 2005 Posts: 36 View ShaneB's Gallery	Report This Post! I have thought about making a panel sled for my table saw, however, I have a craftsman that has awful miter slots. They are almost like a "T slot" and have small notches every couple of inches to keep the miter slides from lifting. It makes retro-fitting other miter slide jigs difficult. I am thinking of cutting the notches off if the miter slot is the same size as standard slots. Thanks for the info guys.
	Top - Reply with Quote

06-12-2006, 07:53 PM	#5
ShaneB Registered User Dedicated Member Join Date: Sep 2005 Posts: 36 View ShaneB's Gallery	Report This Post! Bob, I can't quite figue out the jig in your photos. It appears to be just a straight edge to me. How does the saw portion of the jig ride along the straight edge? Shane
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06-12-2006, 08:36 PM	#6
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,256 View bobj3's Gallery	Report This Post! Shane It's a L shape alum stock, it hooks in the channel of the quick clamp. You don't need to hold it down just a light push on the saw and it will track true. The 1/16" carb.bit saw blade will give you a clean cut with almost no rip outs on plywood. ----------------- Look real close at the black bracket in the snapshot http://www.routerforums.com/attachme...achmentid=2505 part of the ( L ) bracket is deep inside the slot,about 1/32" from the bottom of the slot I used the MDF stock to set the depth of the lock in part of the L. Just a side NOTE**I made one for the router also and it works great for Dado's and anything that you want to use it on. http://www.routerforums.com/table-mounted-routing/2634-issues-cutting-dovetail-dados-table-router.html Just a note about the Craftsman Table Saw. When you make a Panel cutting jig you need to make a T-slot that will fit the saw table, I have the same saw and I will post a snapshot if you want to take a look at it. It's two part T-Slot fixture and it works great in the saw table. Just ask and I will post a snapshot. Bj __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J. Last edited by bobj3; 06-12-2006 at 09:18 PM.*
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06-13-2006, 01:54 AM	#7
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,256 View bobj3's Gallery	Report This Post! Shane Here are some snapshots how to make a panel cutting jig for the Craftsman table saw. Hope they help you Bj Attached Thumbnails __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J.
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06-13-2006, 07:25 AM	#8
Mike Senior Moderator Supreme Forum King Join Date: Nov 2004 Location: Detroit, Michigan USA Posts: 3,372 View Mike's Gallery	Report This Post! You could also make the guide strip from a piece of hardwood by cutting a strip 1/2 x 5/8" and removing 1/16x 1/4" deep from each side on your router table. UHMW is the ideal material since it is "self lubricating" but HDPE would work well too. __________________ Mike Please edit your profile with a name and location so we can better assist you.
	Top - Reply with Quote

06-13-2006, 08:26 AM	#9
ShaneB Registered User Dedicated Member Join Date: Sep 2005 Posts: 36 View ShaneB's Gallery	Report This Post! You're the Best Bob! I can't believe that you have the same saw. I have been scratching my head over this for months. Thank you so much. I plan to make one this weekend.
	Top - Reply with Quote

06-13-2006, 10:34 AM	#10
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 8,256 View bobj3's Gallery	Report This Post! You're Welcome Shane Post a picture or two after you make it this weekend. NoTE **Besure to put your plywood blade in the saw b/4 you start. Plus use your zero insert plate in the saw top. If you don't have one just remove the one from the saw and use the plastic you have left over to make 2 1/2' X 10" long insert,you will need a rubber gromett under the back side on the insert and a 3/16" steel washer under the front one.(the grommet will compress down and hold the plate in place) You will also need to put a rabbit on 3 sides on the insert 1/4" wide 3/16" deep ,this will let the insert set right in the hole.(on the alum.tabs ) Place it in the saw table screw it down and move the blade up ( with care) now you have one. Make two or three at the same time,they are nice to have on hand. The 1st one I made (in the snapshot ) told me the saw blade was off a bit so I did fix that now the blade cuts true,that's hard to see in the Fac.insert because it's so wide of a slot. 60/80 tooth Blade This will cut the plastic a bit cleaner and when you cut the panel sled it will be just right when you cut the plywood for the panels. Then it's set for dead on cuts and you can add a stop block on the right end side then you can cut them all the same size. In the snapshot you will see my combo blade in place don't use yours,see notes. One more NOTE about the table saw, I didn't care for the chip bag under the table so I took it off and put in a plastic flower pot ,hahahahaha I know,you know that it has a plastic part to hook the bag on to under the table saw, I found a plastic flower pot that was just the right size,for two bucks and some black paint and 4 screws, it looks like a fac.part,I put in a hole to hold the app. and the vac hose now all the chips get put into the vac system bag. see snapshots how to put one in your Craftsman Saw. Have a good one Bj __________________ PodCast videos RWS on YouTube http://www.routerforums.com/86898-post1.html Besure and click on the Up Arrow key ▲ on the Youtube video, you can select other youtube videos on router tables http://www.woodworkingonline.com/?s=dovetail Machine Cut ▼ http://www.woodworkingonline.com/200...cut-dovetails/ http://www.woodworkingonline.com/woo...podcast-store/ http://www.woodshopdemos.com/menu2.htm Bob J. Last edited by bobj3; 06-14-2006 at 10:17 AM.*
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