How to Use a Circular Saw on Plywood

Circular saws are a great addition to any toolbox.

Cutting a full-size four-by-eight sheet of plywood can be a challenging task. Cutting plywood with a hand saw can leave a crooked edge, while the size and weight of plywood make it difficult to cut with a table saw. The easiest and safest way to cut plywood is to use a circular saw. Circular saws are small yet powerful saws that are inexpensive and easy to use and allow you better control when cutting plywood.

Things You'll Need

• Circular saw
• 4- by 8-foot sheet foam insulation 1 inch thick
• Tape measure
• Straight two-by-four
• C-Clamps

Instructions

1. Place a 4- by 8-foot piece of 1- to 2-inch thick foam insulation board on a flat surface large enough to accommodate the insulation and allow you ample space to move around it. Place the plywood sheet on the insulation and ensure that the side of the plywood with the better finish is facing down. This prevents the saw from chipping or splintering the good side of the plywood.

2. Set the cut depth of the circular saw to 1/4 of an inch greater than the thickness of your plywood. Refer to your specific saw's instruction manual for determining how to set the cut depth. Measure and mark the cut line you will need to make on the plywood. Measure the distance from the blade of the circular saw to the left hand edge of the saw base. This measurement will be the "blade distance."

3. Clamp a straight two-by-four to the plywood using c-clamps. The two-by-four should be positioned so that the edge of the board is exactly the blade distance from the line you need to cut. This will allow you a hard edge to guide the saw while making the cut.

4. Prepare to start the cut by placing the base of the saw on the plywood and the edge of the base against the two-by-four. Ensure the blade is not touching the plywood. Start the saw and barely nick the plywood with the blade. Stop cutting and verify the cut will be in the correct position. Adjust the position of the two-by-four if needed in order to correct.

5. Place the base of the saw back on the plywood and position the edge of the base back against the two-by-four. Start your cut and ride the edge of the saw along the two-by-four guide to get a straight cut.

Tips & Warnings

• Clamp the two-by-four on the piece of the plywood you need. This way, if the saw wanders from the two-by-four, it won't ruin the piece you're keeping.

• Keep saw blade away from body at all times or serious injury may occur.

References

• Woodworking Tips: Cutting Plywood Down to Size

Resources

• BenchMark: Cutting Sheet Goods