From: adp@druwy.ATT.COM (PessotA)
Newsgroups: rec.woodworking
Subject: Re: Cutting sheet goods - best way?
Summary: panel saw, cutting sheet goods
Date: 29 Jul 92 14:02:04 GMT

In article <92210.11331134AEJ7D@CMUVM.BITNET>, 34AEJ7D@CMUVM.BITNET writes:
> Problem:  Cutting 4 X 8 sheets of [whatever] with sufficient accuracy and
> reproducibility for cabinet work. I can't afford a shop-model panel saw,
> and the "cutting guides" I've seen so far (Exac-T-Guide, Blade Runner II,
> etc.) leave a little to be desired. I've been "muddling through" with
> a portable circular saw and a straight edge, but it isn't an ideal solution
> at all.
> 
> Anybody got any good suggestions for solving this headache?
> 
> Thanks in advance.
> 
> 
> Sez me,
> 
> W. K. (Bill) Gorman

I think the ideal tool for doing this is a panel saw which most
of us don't have. Though now I am happy to say I do.
Several weeks back there was interest in home made panel saws.
I didn't see any suggestions posted on that topic, but waited
anxiously. Then I received Issue No.4 of Woodsmith's Shopnotes.
Their feautured shop project in that issue was a panel saw.

I decided to go for it. After 2 evenings and a weekend, I had
a sturdy, very functional, fairly accurate panel saw.
Total cost, $75 for wood (1 sheet 3/4 birch ply, 8 2x8's)
and $130 for hardware (I ordererd the kit from Shopsmith
because I was having trouble located all the right sizes
for the various hardware and felt that improvising would
compromise the accuracy of the saw).
This does not include the cost of a circular saw.
I would guess most of us have one lying around already.
Its big and pretty heavy, but moves around my garage on wheels
and can be folded up against a wall when not in use.

Since finishing it, I've cut up ~20 sheets of plywood and I can say
while it does need improvements, it beats the hell out of
laying each sheet on the floor over a piece of styrofoam insulation
and lining up every cut.  At the moment I rough cut to within 1/4 "
and then cut to final on my table saw. I think my 10 year old
B&D circular saw is keeping me from making precise cuts right on the
panel saw. The blade is dull and the arbor has too much in-out play
in it.

If anyone is really interested, see Shopnotes Issue 4.
I can also respond to anyone who has any specific questions.

Below is a pretty good (I think) ascii drawing of the saw.


                     --------------  top rail 
                     ---*-----*----
                    /   * | | *    \
                   /   -*-----*-    \
                   /   |* SAW *|    \
                  /    |*     *|     \
                  /    -*-----*-     \
                 /      * | | *       \
                 /      * | | *       \
                / pipe->* | | *<-pipe  \
                /       * | | *        \
               /        * | | *         \
               /        * | | *         \
              /         * | | *          \
              / plywood * | | * plywood  \
             /  bed     * | | * bed       \        ----- extension
             /          * | | *           \        v
 ___________/           * | | *            \___________ 
|           /           * | | *            \           |
|=======================* | | *========================|<- material
|__________/            * | | *             \__________|   rest
           -------------*-----*--------------
           ---------------------------------- bottom rail



Al Pessot
AT&T Bell Labs Denver
att!druwy!adp
Newsgroups: rec.woodworking