How To Cut Plywood With A Circular Saw - The Easiest Way

Cutting plywood can be challenging due to its large size and weight, making it difficult to handle and maneuver. This is especially true if you don't have access to a table saw. However, with the right tools and techniques, you can easily learn how to cut plywood by hand or how to cut plywood with a circular saw, without a table saw. In this guide, VINAWOOD will show you how to cut plywood to achieve clean, precise cuts using a circular saw and other handy tools, ensuring your DIY projects are a success.

Things to know before cutting plywood

Before learning how to cut plywood, you need to know the difference between rip cut and cross cut, best blades for plywood cuts, tips to prevent tear out

Rip cut and cross cut

A rip cut runs parallel to the grain of the wood, meaning it follows the length of the plywood sheet. In contrast, a cross cut goes across the grain, cutting along the width of the sheet.

Cross cuts are much more prone to tear out compared to rip cuts, so it's important to be extra cautious when making these cuts.

Best blades for plywood cuts

The best way to avoid tearing out when cutting plywood is to use a high-quality plywood blade, regardless of the type of saw you're using. Ensure that your saw blade is labeled "plywood," "finish," or "fine finish." These blades have a high tooth count, which allows them to cut the wood much more cleanly, reducing the risk of tearing. For example, a 60-tooth blade is ideal for cutting plywood with a circular saw.

Tips to prevent tear out

When using a circular saw, the blade's rotation causes the teeth to cut upwards, making the top side of the plywood more susceptible to tear out than the bottom side.

To minimize this, flip your plywood sheet so that the "good" side (the side you want to be visible) is facing down. This way, any tear out that occurs will be on the "bad" side.

For instance, if you're constructing a dresser, you can position the "bad" side facing inward, hiding any tear out in the finished piece.

Another effective method to prevent tear out is to apply painter's tape along the cut line before you start cutting. The tape helps hold the wood fibers in place as the saw blade passes through, reducing the risk of tearing.

> Read more: 1/8 inch plywood, 15/32 plywood, 19/32 plywood, 5x10 plywood

Tools needed for cutting plywood

Here are the tools needed when cutting plywood and how they work. Below are three commonly used tools for cutting plywood:

• Circular Saw

• Kreg Rip Cut

• Kreg AccuCut

The Rip Cut and AccuCut are handy guides that attach to the base plate of your circular saw. Although they aren't absolutely necessary, they are incredibly useful for making quick and accurate cuts.

Alternatively, you can use a long straight edge and some clamps, but this method requires significantly more setup time for each cut.

Rip Cut and AccuCut guides

Both the Rip Cut and AccuCut guides come with a universal sled that attaches to your saw’s base plate using set screws. Once attached, this sled can be used with either guide.

The sled slides onto the Rip Cut rail and clamps in place. You then guide the straight edge along the plywood to make cuts up to 24" wide. The Rip Cut is perfect for ripping plywood into smaller strips but is limited to 24" wide cuts. This is where the AccuCut shines. The AccuCut acts like a track saw, with 2' track sections that can be extended up to 8'. This allows you to make longer cross cuts across the plywood.

You can use the Rip Cut for ripping and the AccuCut for cross cutting. If possible, you should have both for versatility.

> Get more details: pine plywood, ac plywood, bamboo plywood, bendable plywood,poplar plywood

How to cut plywood with a circular saw

A circular saw, also known as a skill saw, is frequently used to cut plywood. However, making long, straight cuts can be challenging without a jig or guide. To solve this, you can clamp a board along the length of the plywood to serve as a guide for your saw, ensuring straighter cuts. Below are detailed instructions on how to cut plywood with a circular saw. It also includes some  tips to help you do better.

Step 1: Setting up plywood cutting “station”

Set up a stable work surface. Use sawhorses or a workbench to support the plywood. Ensure the plywood is well-supported to prevent it from bending or breaking during the cut.

Step 2: Setting up circular saw

To set up the Kreg Rip Cut and AccuCut guides on your circular saw, follow these steps:

1. Attach the sled to the saw base. Use the two set screws at the top of the sled to tighten it securely to the base plate. Ensure the sled is square to the saw base and not crooked and adjust the depth of your circular saw blade so that it is just slightly deeper than the thickness of the plywood. This will help you achieve a cleaner cut.

2. Follow the detailed setup instructions provided with the guides. These instructions will explain how to dial in the guides for your specific circular saw.

3. Practice cutting and adjusting the guides as needed. It may take a few practice cuts to get the guides set up perfectly. The AccuCut should be set up first, followed by the Rip Cut.

Tips:

• Use a fine finish/plywood blade on your circular saw when cutting plywood.

• Dedicate a circular saw for plywood cutting if you do a lot of it. This saves setup time and ensures more accurate cuts.

• If you don't have a dedicated plywood saw, make sure to remove the sled before using the saw for other purposes.

Step 3: Ripping plywood sheets to desired widths

Ripping plywood sheets with the Kreg Rip Cut guide is a straightforward process. Here's how to do it:

1. Set the indicator tab. Align the red line on the indicator tab with your desired width using the built-in ruler on the guide.

2. Clamp the guide in place. Slide your circular saw with the attached sled onto the guide and flip the gray tab over to secure it.

3. Double-check the width. Use a tape measure to verify that the distance from the blade to the guide matches the desired width. Ensure the blade kerf is on the waste side of the piece.

4. Set the blade depth. Adjust the blade depth to cut slightly deeper (1/16 – ⅛″) than the plywood sheet.

5. Make the cut. Start at one end of the sheet and cut along the edge, keeping the guide pressed firmly against the plywood. Maintain a square cutting motion.

6. Repeat for additional strips. Continue ripping the plywood sheet into strips of the desired width.

Tips:

• Clamp the plywood securely to your work surface to prevent it from moving during the cut.

• Use a fine-tooth blade designed for plywood to minimize tear-out.

• Wear safety glasses and gloves when operating power tools.

Step 4: Cross cutting plywood sheets to desired length

How to cut plywood? Cutting plywood sheets to desired lengths can be done using either a miter saw or an Accu-Cut guide, depending on the width of the plywood strips.

Miter saw (if plywood strips are smaller than 16″ wide):

1. Use a fine-tooth blade to minimize tear-out.

2. Set the miter saw to 90 degrees for a straight cut.

3. Measure and mark the desired cutting length on the plywood strip.

4. Align the plywood strip with the miter saw fence and secure it in place.

5. Slowly lower the blade and make the cut.

Accu-Cut (if plywood strips are wider than 16″ wide):

1. Use a square to mark the desired cutting length on both sides of the plywood strip.

2. Ensure proper support for the plywood strip to prevent sagging and blade pinching.

3. Align the cutting edge of the Accu-Cut guide with the marks.

4. Place the Accu-Cut guide on the "good" side of the mark, ensuring the blade cuts on the "waste" side.

5. Run the circular saw and sled down the Accu-Cut guide to make the cut.

6. Wipe off dust and debris from the grips and plywood surface if the guide slips.

Tips:

• Wear safety glasses and gloves when operating power tools.

• Use a sharp blade for clean, accurate cuts.

• Support the plywood strip adequately to prevent accidents.

• Double-check measurements before cutting.

Step 5: Start Building

With your plywood cut to the desired sizes, you can now start assembling your project. Whether you're building furniture, cabinets, or any other project, accurate cuts are the foundation of a successful build.

> Discover more: burnt plywood floor, plywood edge banding, plywood garage walls, plywood kitchen cabinets

Some other ways to cut plywood

Here are some other methods for cutting plywood that you can consider.

How to cut plywood with jigsaw

For cutting plywood into circles or intricate patterns, a jigsaw is ideal. While it can make straight cuts, it's more challenging. Ensure the jigsaw's cord is long enough to reach your cutting area. Use a 20 teeth per inch blade with in-line teeth and lock the angle or depth adjustment knobs before starting.

> Learn more: 

• how to cut plywood
• what is plywood used for
• when was plywood invented

How to cut plywood with a knife

To cut plywood with a knife, use a sharp blade to avoid splintering. Guide your cuts with a straight edge or metal ruler. Cut slowly and steadily, letting the blade do the work. Make several passes rather than cutting through in one go.

How to cut plywood with a Handsaw

Cutting plywood with a handsaw isn't the fastest or most precise method, but it's effective for a few cuts. Start with a sharp blade, preferably a miter handsaw for smaller cuts. For longer, straight cuts, use a stiff board as a guide and clamp it along your cut line. Cut only on the push motion to maintain control. For larger saws, use the stiffer part of the blade near the handle to prevent bending.

How to cut plywood with a table saw

Handling a 4' x 8' sheet of plywood on a table saw can be risky, so always get help. For a clean cut and less chip-out, set the blade height to its maximum and place the good side face-up. Maintain steady pressure on the fence while feeding the plywood, and have someone catch it at the other end without applying pressure to ensure a straight cut.

FAQ regarding how to cut plywood

What is the best tool to cut plywood?

The best tool for cutting plywood is a circular saw. It's portable, user-friendly, and makes straight cuts quickly and accurately.

How to cut a sheet of plywood by yourself?

To cut plywood by yourself, use sawhorses for support, clamp a straight edge as a guide, and score the cut line with a utility knife. Use a fine-tooth blade on a circular saw, cutting only on the push motion for precision.

What is the best way to cut plywood straight?

To cut plywood straight, use a stiff board as a guide. Clamp it along your cut line to act as a jig. For the best results, cut only on the push motion of the saw, not the pull. This technique helps you slow down and make more precise cuts.

How to cut plywood without splintering?

To prevent splinters, use a ruler and a Stanley knife to score along the cut line before sawing. Additionally, apply painter's tape to both sides of the sheet and mark the cutting line on the tape. This method works well with various saws.

The above article has instructions on how to cut plywood. Cutting plywood doesn't have to be intimidating. With the right tools and techniques, you can achieve clean, precise cuts every time. Remember to choose the right blade, use guides to help with straight cuts, and take your time to prevent tear out. 

VINAWOOD – Vietnam Plywood Supplier & Manufacturer