Plywood is a versatile and affordable material that can be used for various woodworking projects. Whether you want to make furniture, cabinets, shelves, or other DIY crafts, plywood can be a great choice. But how do you cut plywood to the desired shape and size? Can you use a jigsaw to cut plywood?
The answer is yes, you can cut plywood with a jigsaw. A jigsaw is a handheld power tool that can make curved and straight cuts on different materials, including plywood. However, cutting plywood with a jigsaw requires some skills and techniques to get a smooth and accurate result. In this article, we will show you how to cut plywood with a jigsaw and what factors you need to consider before you start.
One of the most important factors that affect the quality of your plywood cut is the blade you use. Jigsaw blades come in different types, sizes, and tooth configurations, and each one is designed for a specific material and purpose. For plywood, you need to choose a blade that is sharp, durable, and suitable for the thickness and density of your plywood sheet.
Generally, there are two types of jigsaw blades: high carbon steel (HCS) and high speed steel (HSS). HCS blades are softer and more flexible, but they tend to wear out faster and produce rougher cuts. HSS blades are harder and more resistant to heat, but they are more brittle and prone to breaking. For plywood, HSS blades are usually a better option, as they can cut through the layers of wood without dulling or bending.
Another factor to consider is the tooth pitch of the blade, which is the distance between two adjacent teeth. The tooth pitch determines how fast and smooth the blade can cut through the material. A finer tooth pitch (more teeth per inch) produces a smoother cut, but it also cuts slower and generates more heat. A coarser tooth pitch (fewer teeth per inch) produces a faster cut, but it also creates more splintering and tear-out. For plywood, you need to balance the speed and smoothness of the cut, so a medium tooth pitch (10 to 12 teeth per inch) is usually recommended.
Before you start cutting, you need to prepare the plywood sheet to ensure a safe and accurate cut. Here are some steps you need to follow:
Measure and mark the cut line on the plywood sheet. You can use a pencil, a ruler, a tape measure, or a compass to draw the cut line. If you want to make a curved cut, you can use a flexible curve ruler or a string to mark the curve.
Clamp the plywood sheet to a sturdy work surface, such as a workbench or a sawhorse. Make sure the plywood sheet is flat and stable, and the cut line is overhanging the edge of the work surface. This will prevent the blade from hitting the work surface and damaging it.
Apply masking tape or painter’s tape along the cut line on both sides of the plywood sheet. This will help reduce splintering and tear-out, as the tape will hold the fibers of the wood together and prevent them from chipping off. You can also apply a thin layer of wood glue on the tape to further strengthen the bond.
Insert the jigsaw blade into the jigsaw and adjust the speed and orbital settings. The speed setting controls how fast the blade moves up and down, and the orbital setting controls how much the blade moves forward and backward. For plywood, you need to use a moderate speed and a low orbital setting, as this will produce a smoother and more precise cut.
Cut the Plywood Sheet
Now that you have prepared the plywood sheet and the jigsaw, you are ready to cut. Here are some tips to follow:
Start the jigsaw and let the blade reach full speed before touching the plywood sheet. Align the blade with the cut line and gently press the jigsaw against the plywood sheet. Do not force the jigsaw or push it too hard, as this will cause the blade to bend or wander off the cut line. Let the blade do the work and guide the jigsaw along the cut line with a steady hand.
Follow the curve of the cut line as closely as possible. If you need to make a sharp turn, stop the jigsaw and reposition it before continuing the cut. Do not twist or tilt the jigsaw, as this will cause the blade to bind or break. Keep the jigsaw base flat and parallel to the plywood sheet at all times.
Cut slowly and carefully, especially near the end of the cut. Do not rush or jerk the jigsaw, as this will cause the plywood sheet to splinter or crack. Support the plywood sheet with your free hand or another clamp to prevent it from falling or breaking. When you finish the cut, turn off the jigsaw and remove the blade from the plywood sheet.
After you cut the plywood sheet, you need to finish the cut edge to make it smooth and clean. Here are some steps you need to follow:
Remove the masking tape or painter’s tape from the cut edge. Peel off the tape gently and carefully, as it may still have some wood fibers attached to it. If the tape is too sticky or hard to remove, you can use a hair dryer or a heat gun to soften the glue and make it easier to peel off.
Sand the cut edge with sandpaper or a sanding block. Use a fine-grit sandpaper (120 to 220 grit) to smooth out any rough or uneven spots on the cut edge. Sand along the grain of the wood and avoid sanding across the grain, as this will create scratches and marks on the cut edge. You can also use a file or a rasp to remove any burrs or nicks on the cut edge.
Apply a coat of wood filler or wood putty to fill any gaps or holes on the cut edge. Use a putty knife or a spatula to apply the filler or putty and smooth it out. Let the filler or putty dry completely and then sand it again with fine-grit sandpaper. You can also use a wood stain or a wood finish to match the color and texture of the plywood sheet.
Conclusion
Cutting plywood with a jigsaw is possible and easy, as long as you follow the right steps and techniques. By choosing the right blade, preparing the plywood sheet, cutting the plywood sheet, and finishing the cut edge, you can achieve a smooth and accurate result. A jigsaw is a versatile and handy tool that can help you with various woodworking projects involving plywood. We hope this article has helped you learn how to cut plywood with a jigsaw and inspired you to try it yourself. Happy cutting!
