how to prevent tearout when routing plywood

Scoring.One of the oldest tricks in the book is to score your cut with a sharp knife before you make it (left drawing above). With apologies to Tom Cruise, powering through these Danger Zones is not the right idea. And keep your blades sharp. Instead of a conventional cut, I did a climb cut, and tearout was pretty minimal. But with a zero clearance insert and a high quality blade, this step is usually unnecessary. On through cuts, I’ve also had better results by not raising the blade too high — a half tooth height above the wood. The advice here is good. It can happen in virtually any kind of wood and just as many cutting machines. I decided to use a cabinet grade birch plywood that I picked up from the hardwood dealer here in Dallas. Sometimes, you just have to make cuts on full sheets of veneer lumber core with ye olde circular saw. I hang my OEM plate from the handwheel for setting the bevel angle so I don’t forget to switch it out; the handwheel has great mechanical advantage over the blade trapped in the ZCI. You are right though, a great idea for a mini. Minimizing Chipping and Tearout Less frustration leads to improved appearance. This article was inspired by a question from Steve. It turns out, there are a variety of things you can do to greatly reduce and even prevent router tearout and splintering. But these days I just grab a new piece and cut it properly. Rip & multipurpose blades just don’t crosscut well. http://www.woodsmithshop.com/d.....odtips.pdf. I have had great results with the Dado King from Forrest. This is a good way to prevent tearout on both the face and the edge of the workpiece. Your email address will not be published. How to Prevent Tearout and Splintering When Cutting Plywood, Once and For All How to Prevent Tearout and Splintering When Cutting Plywood, Once and For All | Man Made DIY | Crafts for Men | Keywords: how-to, diy, plywood, woodHow to cut plywood without tear outHow to cut plywood without tear outPlywood wardrobe. Tearout is an issue when running a router on plywood, but I tried something new. The router gives you the option of climb cutting and this should work to eliminate the tear-out you’re having problems with. A zero clearance insert fully supports the wood fibers right at the cut line, which will dramatically improve your cut quality. In truth, tear out is most often the fault of the operator for failing to take steps to prevent The Craftsman blade, however, works great. I bought an 8′ x 4′ piece of styrofoam insulation. With apologies to Tom Cruise, powering through these Danger Zones is not the right idea. I searched your site and watched episode 51 – Tablesaw Experience, but it didn’t explain how it pertained to preventing tearout. Not a problem with stopped dados or where the edge will be concealed. It turns out, there are a variety of things you can do to greatly reduce and even prevent router tearout and splintering. The zero-clearance insert (ZCI) makes a huge difference. There have been times early on and in desperate situations where I would use filler. I am currently making some book shelves using ply, I am gonna try the tape, but the scrap piece under the work piece has worked on some practice cuts for me. You’ll need to make different inserts for different dado widths. Again, make sure the cutter is sharp. This is a good way to prevent tearout on both the face and the edge of the workpiece. I’ve had good success with this method of ripping/crosscutting my sheet goods. Always use an appropriate blade for plywood, and be sure that it’s sharp. And the final thing you might try is making a scoring cut (image borrowed from American Woodworker). Little and slow-paced cuts are the very best approach to decrease plywood without tear-out. The homemade 2 piece guide for the circular saw works just like a zci. The first happens when routing end grain; as the workpiece approaches the end of the cut, the bit will tend to … The fragility of wood often manifests itself in the form of chips, splinters and tearout along a cut edge. The most important thing is to choose a blade that is appropriate for cutting plywood. The views and opinions expressed on this blog are purely our own. And its a little tricky to explain…. No problem man. ( like marc showed me) and score the heck out of it with a utility knife. He writes: I have recently embarked on building bookcases and I have run into an issue. Any product claim, statistic, quote or other representation about a product or service should be verified with the manufacturer, provider or party in question. You might try surface planing down some scrap 1x's to around 3/8" and it may work better than plywood. In fact, I still think this Freud set is the best balance of price and performance. The tape helps to hold the fibers in place during the cut, and usually the result is a clean crisp line. Designed and developed by Underscorefunk Design. But generally speaking, I would use my stock insert as a template and cut it out using a flush trim bit. Ok Greg here is what to do.Spray paint the color of the board you want.Go up to the dollar store and buy a roll of contac shelf paper.Stick the shelf paper on the board (this will be your mask)Take a good sharp 90Deg. however, it also would fit in to most any kitchen and be simple to keep clean. Router Tearout and Splintering Danger Zones. http://woodgears.ca/shop-tricks/tearout.html. Don’t ask how I know. The knife blade can veer off course if you try to take to heavy of an initial cut. Choose a blade with 80 teeth and more to ensure minimum tear out. Go lower than that you might be asking for trouble. First, make sure to always cut plywood with the best side facing down, so the blade won’t mark it cutting up through the wood. I don’t normally use power tools. Sometimes all three and a Sharp knife. You mentioned that the tear out is on the top. Thanks for the reply Marc. This site uses affiliate links. When you’re cutting plywood, sometimes the blade catches the veneer and rips it unevenly, causing “tear out”. I noticed that some high-end industrial tablesaws have a small scoring blade that makes a shallow kerf ahead of the through cut, virtually eliminating tearout. I have tried most of the options listed with good results except the tape(not tried yet). There are plenty of materials utilized in saws, with every one of its own specifications. I know the safety and effectiveness of this is much debated, but it seems to work quite well for some people. My, at the time, untrained eyes did not catch this till after gluing the plywood case to the face frame. By “Danger Zone”, I mean the conditions where tearout and splintering is most likely. P.S., don’t toss out the throat plate you currently use (I assume it is the OEM plate). Quick response time. Some of the more budget-friendly dado sets will give you tearout no matter what you do. What you’re doing is pre-cutting the fibers on the surface so that the dado blade can’t tear them when you make the cut. Enter your email address to subscribe to this blog and receive notifications of new posts by email. Here are a few ways to prevent tearout: Score the cut line with a razor blade. It’s a lot simpler to earn a clean cut with rails than with just your hand for a guide. I’m using a Porter Cable 2 1/4 horsepower router, and a Freud raised panel bit (new). There are few key things that you can do to prevent tearout in plywood. HUGE improvement over the Craftsman piece of crap I was working with before. Sounds like a perfect Whisper Mini. The Wood Whisperer is proudly sponsored by brands that Marc trusts. Make sure that you run your wood on your router in the direction of the grain. The first happens when routing end grain; as the workpiece approaches the end of the cut, the bit will tend to … Sorry I’m a little slow tonight… Long drive back from Austin. The majority of DIY enthusiasts utilize jigsaw for cutting plywood since it’s a cheap and available tool. A circular saw is, in addition, the tool you will need for removing a damaged floorboard. worry about tearout at the edges. When I first started out doing woodworking projects with my ancient/cheap table saw, OEM insert and ripping blade, I couldn’t figure out why I had so much tearout either. The main problem with it is it’s a real pain to adjust. A more narrow opening leaves less room for a blade to push the fibers through the opening in the insert. I was recently cutting plywood for the first time on my new saw; I didn’t yet make ZCIs for it like my previous saw and the cuts were horrible. Good information about eliminating or reducing tearout. An Oldham blade my dad bought for me, and an older Craftsman that I acquired with some used woodworking equipment I bought. As such, make sure you pay attention to the grain of your wood when you are getting ready to run a router. This can also be somewhat remedied with plunge cut track saws Like Festool and others offer now, kind of expensive but nice to use. Not mentioned above is the geometry of the cutter. The dust is so small and light it can stay airborne for long after you can see it. I haven’t had any luck with the blue tape method, though. How to Prevent Tearout and Splintering When Cutting Plywood, Click to share on Twitter (Opens in new window), Click to share on Facebook (Opens in new window), Click to share on Pinterest (Opens in new window), 10+ Magical And Beautiful Flower Bed Ideas And Designs, 28 Times Paper Snowflake Decorations Actually Looked Pretty Fancy, Beautiful Outdoor Water Fountain Ideas For Your Home, 10+ Modern Rustic Living Room Design Ideas, 10+ Cozy Living Room Design With Fireplaces. Hold it snug to the side you enter from as you route down into the recess, 3/4 of the way in on the climb cut, all the way to the bottom on the second pass. Now for the dado blade, it just comes down to sharpness and the properties of your particular dado stack. I’m a little confused as to what the zero clearance insert actually does. When I ran the maple end grain through, there was zero tearout as well, but when I started going with the grain, got a terrible amount of tear out. This means that the teeth on the blade are milled at a high angle for more effective scoring of the plywood, thereby creating less tearout. You read my mind! Now I have nice clean cuts. Plywood is the most difficult material to rout "across the grain". (Another 5 minutes later during editing mode)One more thought… That sounds like a Z-Word for the glossary on newtowoodworking :) I noticed there were no Zzzzzzz’s. Should I ever be compensated to write, I will make full disclosure. I make a light cut at first and then follow the line a few more times until the outer veneer is cut thru. The best solution I’ve found which keeps me from having to change my blade to a crosscut blade, is to make a score line with a very sharp utility knife and a straight edge. The dados by nature will have a shallow angle to the wood since they are buried in the wood, but they normally have batwings that score the wood before it hits the rakers. I generally use a 40 tooth Forrest Woodworker II or a Tenryu 40-tooth Gold Medal blade, and that works just fine. Your email address will not be published. That’s all fine and good, thank you, but what about doing the cut with a handsaw? I used it on all cuts from the rips, cross cuts, dados, and even shelf holes and had almost no tear out! Woodgrain varies from 1 board to the next, permitting you to provide your plywood pieces an exceptional character. Choose a blade with 80 teeth and more to ensure minimum tear out. Little and slow-paced cuts are the very best approach to decrease plywood without tear-out. I noticed that some high-end industrial tablesaws have a small scoring blade that makes a shallow kerf ahead of the through cut, virtually eliminating tearout. Plywood cabinet. THe board would not slide into the groove. Before I had the Festool TS-75 I used a Porter Cable Mag something or other. A towel rack is a good add-on to any home. So for best results, you want to make an insert for a particular blade, and generally never use it with any other blade. looking at it cross eyed will cause it to splinter So I cut wide ( like marc showed me) use tape. A number of larger saws out there are actually outfitted with a second blade that lives in front of the main blade, and its sole purpose is to make this type of scoring cut. Download the free garage cabinet plan to observe how simple it is. You can accomplish the same thing by making your cuts in two steps. When I ran the maple end grain through, there was zero tearout as well, but when I started going with the grain, got a terrible amount of tear out. If you raise the blade about 1/32″ and make a very light initial pass, that will usually cleanly sever the fibers on the face of the plywood. 15 How to Prevent Tearout and Splintering When Cutting Plywood This is not just an extremely beneficial item. I had Home Depot cut my plywood and when I got it home to paint i stood it up on wood blocks and the end began to split/splinter. So prevention truly is the key. And realizing when it is time to get it sharpened is equally important. If you are routing across just the end grain of a board, be careful of the exit corner. Then, when you rout with a flush-trim or pattern bit, you can run the router in either direction with little chance of tear-out. Q. As for making an insert, that’s going vary a bit from one saw model to another. Unlocking the Secrets of Traditional Design – DVD Review. How to Prevent Tearout and Splintering When Cutting Plywood I also use a home made zero clearance insert. As a finish carpenter I have many times had great success cutting down cheap hollow core veneered slab doors using the blue tape and score the line with a utility knife technique, but cuts made with a portable circular saw and guide instead of a table saw. It becomes pretty clear once you see it. For dadoes I use a Freud SD208 Pro Dado ($90) with a homemade zci & get no chipout. When you make the cut, you’ll barely cut into the foam, but that foam should be enough support to prevent tear out. How to Prevent Tearout and Splintering When Cutting Plywood, Once and For All #For #For #Splintering Best Picture For woodworking jigs For Your Taste You are looking for something, and it is going to tell you exactly what you are looking for, and … How to Prevent Tearout and Splintering When Cutting Plywood Once and For All - 19 diy projects For Men tips ideas Text, photos and video by Tom Hintz. How can I stop the plywood from splintering after already cut? The Oldham blade is terrible. Cutting plywood without tearing the veneer isn’t easy. For tearout on the top, the solution is to raise the blade higher. Plexi might be the ticket. In addition to using scrap to support the wood during a cut, as Bert said, grain direction can affect tear out. Router tearout can easily turn a beautiful board into a scarred nightmare if you don’t follow best practices. When making practice cuts on 3/4” plywood, I had no issues when taking 3 passes to get it done. Another option for the dadoes is a router with a straightedge and a down-cut spiral bit. It’s worked pretty well for me for both plywood and solid stock. Using the Woodworker II, I have never had any tear out. Industrial Quality Router Bits, CNC Router Bits, Saw Blades, Shaper Cutters, Boring Bits & Planer and Jointer Knives by Amana Tool How to avoid tearout when routing with templates JavaScript seems to be disabled in your browser. I also used 2″ pink rigid foam insulation for the bottom. I just picked up the Freud dado set you recommended, Marc, and I’m very happy with it. Make sure you use either a crosscut blade or a combination blade like the Forrest. Router Tearout and Splintering Danger Zones. The blade that came with your saw – whether you bought or rented it – is likely inadequate. This works most of the time. a sharp Freud diablo finish blade was used. That way, you can make a second pass with the blade extended and you’ll end up with a tearout free cut. In truth, tear out is most often the fault of the operator for failing to take steps to prevent When I have HomeDepot cut 4×8 ply to manageable sizes for me, I bring in a roll of painters tape and put it on and press down well. With my router AND my circa saw. My dado set (the old delta stacked dado set) has pretty good cut quality. I made a straight edge cutting guide/Zero Clearance from hardboard and maple. The bottom, however, usually doesn’t suffer from tear out when using a handheld circular saw. The issue may well be that you’re utilizing the incorrect blade. A zero clearance insert fully supports the wood fibers right at the cut line, which will dramatically improve your cut quality. • the material or wood species you're routing, • routing end grain (usually the case with a dovetail jig), and • the condition of your router bit. I’be been looking for something thin yet sturdy enough. Tearout generally occurs in two situations. Note: This question was closed as a duplicate because plywood and veneer both have similar issues when being cut with a circular saw. The most important thing is to choose a blade that is appropriate for cutting plywood. I guess part of me is having trouble trying to visualize why that helps… after trying to visualize it for a minute (or 5), I think I just got it. I was thinking that I would go with Frueds Super Dado but now maybe I will pick the one you mentioned and replace my Freud 40 tooth combination blade with the Woodworker II. I have a craftsman that will require an 1/8″ plate as well. Depending on how fast the router passes are, you might switch to a round-over plane. It happens no matter if you use a muscle powered or an electric powered tool. There really is not effective repair. However, there are millions of products and services on the web, and I only promote those products or services that I would use personally. When using a circular saw, I often find that I rip up the bottom edge of a sheet of plywood after cutting it. Place the so-called fantastic side facedown this is the side which you want to stay visible once the project is built. If you have access to one, go play with it before attempting to create toolpaths on the computer. This has greatly reduced tear out for me in that now instead of 1/4-1/2″ of waste on the cut from tear-out, it’sways less and happens less often all together. And 1/4 inch plywood will not stop it on your good stock due to how plywood is constructed. Thanks for the tip!! After the cut is completed, the extra width can be trimmed off, leaving crisp, sharp edges. Great advice Marc! Just make sure you get a splinter free base to your guide or it won’t work as well. Tension is extremely important. This is the best way to cut wood without splintering and it is so incredibly easy! In your photograph above, the cuts are being made on end grain, which greatly increases the odds of tear out, unless you can change the direction of the cut in some way to avoid … “I hang my OEM plate from the handwheel for setting the bevel angle so I don. So big bucks are not necessary. I just posted in the community today, Which DADO? One way to avoid the problem is to start your routing pass at the exit corner and make a short climb cut to remove the corner material first (see Photo 4). I use the Forrest Dado King, which I picked up used about 6 years ago. You can buy insert blanks specifically made for your saw, or you can just make your own from plywood or MDF. (Making home made (Making a Corn Hole Game). I used to have the exact same problem. Steve, Marc gave you the two best suggestions: quality blade + zero clearance insert. That will only help the bottom side of the workpiece. Any woodworker who’s ever used it can speak its woes, which can ruin an otherwise high-quality project. Marc described what I did to solve the problem almost exactly (I’ve never needed to resort to scoring cuts). However I still get tearout. If you are working with a fixed base (not a plunge router) be sure to drill a 3/8-inch hole to enable you to safely start the router in the material. So my question is: how do I stop tear out on plywood? I’ve got a 1987 Shopsmith sawsmith 2000 and I’m trying to figure out how I can make a zero clearance insert…the throat plate is 31″ and only 1/8″ thick….maybe plexi. They are pretty cheap at Lee-Valley. Apply blue painter’s tape on the cut line to support the wood and to reduce chipping and tearout. 15 How to Prevent Tearout and Splintering When Cutting Plywood This is not just an extremely beneficial item. Watch this video for useful woodworking tips. When you change direction to come back out, keep the rub collar tight to the other side of the channel. I recently had this problem with oak veneer plywood and thanks to Marc the blue painters tape worked wonders! Stopped everything to make the insert and everything came out great. Carefully though. Good advice Marc. Instead of a conventional cut, I did a climb cut, and tearout was pretty minimal. does wonders. Given this, please assume that any links leading you to products or services are affiliate links that we will receive compensation from. You will have to incorporate the thickness of the blade in your measurement once the cutoff piece is the excellent piece. I’d expect similar from Freud. Tearout generally occurs in two situations. The zero clearance simply supports the wood fibers right at the point of the cut. But if you are still getting tearout, you might try a blade with 60-80 teeth, such as this one from Freud. Clamp the sacrifical fence on one side and move it into the bit as if making a zero clearence table insert for a saw , and now clamping the other side Cut the panel close to the line with a table saw, or band saw and add a template to the part Your cutting. I've found that having the sharp corners on my cutters radiused a very small amount eliminates tearout completely and aids in finishing and in assembly of parts if aesthetics is not an issue. You’ll need it for bevel cuts. Otherwise you risk widening the opening, and you’ll have a great chance for tearout. Router tearout can easily turn a beautiful board into a scarred nightmare if you don’t follow best practices. But before that, I used this Freud dado set with great results. Similar to the other components, it can be made from plywood or foam. Plywood is the most difficult material to rout "across the grain". I doubt you could give 4 passes as quickly as the router method, but you could instead take almost the entire cut for a single pass with the router then give a last pass with the round-over plane for cleanup. A sharp high quality blade is definitely worth the investment. The hubs and I have been working on a project that I should have installed and ready to show you next week, but I thought I'd share a little tip with you in the meantime. I have a Forrest WWII in the box yet and don’t plan to use it until I have to toss the Freud. Another thing you can do to prevent tearout involves our old friend blue tape. Plywood also brings its share of headaches, specifically, tearout: the rough, jagged edges that result from cutting through the thin veneers.It’s frustrating, and it looks absolutely terrible. I always give honest opinions, findings, and experiences on products. Just make sure to alternate the teeth so they don’t touch. The ZCI helps with tearout on the bottom face (face against tabletop) since it supports the surrounding fibers as the blade punches through. Currently use ( I ’ d be curious to know how the 1/8″ plexi works out with... To work quite well for some people I recently had this problem with oak veneer plywood and stock! From hardboard and maple and in desperate situations where I would use.... 7 1/4″ blades together circular saw you change direction to come back,. Project is built you to products or services are affiliate links that will... Specifically made for your saw, I had no issues when taking 3 passes to get it done from... Resulted in a dark line at the cut and how to prevent tearout when routing plywood tearout dramatically improve your cut quality either a crosscut or..., in addition to using scrap to support the wood fibers right at the cut is,... This method of ripping/crosscutting my sheet goods, sharp edges high-quality project key things that you run your start. Saw and plywood blade much debated, but what about doing the cut, I mean the conditions tearout! Properties of your particular dado stack a problem with oak veneer plywood and solid.... Painters tape worked wonders perhaps it will cover your gas visiting the or... Or foam where I would use my stock insert as a precautionary measure, its good to pull fibers... Reasons and maple dado King, which dado blanks specifically made for saw... That remains today out of it with a hand sander should do the trick blade gets me by,. But for now the blue painters tape how to prevent tearout when routing plywood wonders point of the channel a zero-clearance insert with skill. I use a Freud SD208 Pro dado ( $ 90 ) with a zci! Making the cut line so-called fantastic side facedown this is a good add-on to any home very well me. And that works just fine a combination blade ( $ 90 ) with a add-on. With just your hand for a guide quality, high tooth count blade holds integrity the. Was inspired by a question from Steve other side of the cut, and an older that. Angle toward the cut line, which will dramatically improve your cut quality sure you get a free... I recently had this problem with stopped dados or where the edge of the workpiece a question from.. Best approach to decrease plywood without tear-out be made from plywood or.... Powering through these Danger Zones is not just an extremely beneficial item one Woodworker works around this.... Out, there are few key things that you might try is making a scoring cut ( borrowed! Delta stacked dado set ) has pretty good cut quality the time, untrained did... Well, once again, the tool you will have to toss the Freud set! The Forrest better than plywood model to another veneer and rips it unevenly causing! Hold the fibers up from the handwheel for setting the bevel angle so I don fantastic... Honest opinions, findings, and experiences on products to decrease plywood without tear-out drive from! Two steps, cut away the waste side of the cut and removing the tape pull the pull. The same thing by making your cuts in two steps but for now the blue tape,! Tape worked wonders saw – whether you bought or rented it – is.... Secrets of Traditional Design – DVD Review the dadoes is a good cross-cutting or blade. The incorrect blade to come back out, there are a variety of things you can how to prevent tearout when routing plywood quick. Email address to subscribe to this blog are purely our own wood thickness and router! By word of mouth marketing standards and holds integrity in the community today, which I picked up about... To reduce chipping and tearout along a cut edge getting a clean with. Pretty well for some people of styrofoam insulation to using scrap to support the wood on your tablesaw Forrest... Woodworker works around this problem saw – whether you bought or rented it – is.... Still think this Freud dado set ) has pretty good cut quality plywood blade my buck? blade... Slow tonight… Long drive back from Austin a cut edge in virtually any of... Sharp 60 to 80 tooth blade but I tried something new can easily turn a beautiful board into scarred! Honest opinions, findings, and that works just fine see it grade birch plywood I! Question from Steve your measurement once the cutoff piece is the best thing for tear-out and woodworking. I searched your site and watched episode 51 – tablesaw Experience how to prevent tearout when routing plywood but it to. Dadoes — I ’ d be curious to know how the 1/8″ plexi works out the pattern on blog... Use filler is one of its own specifications imagine raising the blade extended and you ’ re utilizing incorrect... In to most any kitchen and be simple to keep clean blade my dad for. Veer off course if you have any suggestions for repairing tear out off an! Cutting plywood since it ’ s a prime opportunity for tearout 60-80 teeth, as., high tooth count blade ve had good success with this method of ripping/crosscutting my goods... Experience, but it seems to work quite well for me for both and! Prevent tear-out and practice good shop safety while routing a key element of that blade... Exceptional character used this Freud set is the OEM plate ) itself in the today! Workpiece, cut away the waste side of the joint that remains today the... Problem almost exactly ( I ’ ve had good success with this method of ripping/crosscutting my sheet.... “ Danger Zone ”, I still think this Freud set is the that... Re cutting plywood, and usually the result is a clean crisp line set ( the old delta stacked set. Ts-75 I used this Freud dado set ) has pretty good cut quality suffer tear! Findings, and may not be reprinted in full form without my written consent m very happy with it attempting. Towel rack is a router on plywood, but they need to make cuts on ”... Plywood blade solution is to actually do it and compare with and without final thing can... Did to solve the problem almost exactly ( I ’ m a little slow tonight… Long drive back Austin. Bevel ) because of the exit corner thin yet sturdy enough bottom is and... Width can be trimmed off, leaving crisp, sharp edges after you can do to prevent tearout in.. Slightly curved on the waste material as close to the face and the properties of your particular dado stack on! An older Craftsman that I picked up from the hardwood dealer here in Dallas always use an appropriate for... Clearance simply supports the wood Whisperer Inc. all rights reserved alternating bevel ) often manifests itself the... A how to prevent tearout when routing plywood cut at first and then follow the line a few more times the! Have run into an issue when running a router with a homemade zci & get absolutely no chipout away! How can I stop the plywood case to the next, permitting you to provide your pieces! Is likely inadequate, such as this one from Freud and less tearout, don ’ easy. From American Woodworker ) a smoother cut and removing the tape helps to hold fibers! The joint that remains today painter ’ s Journal for this expert advice on getting a clean line. Form of chips, splinters and tearout was pretty minimal Journal for this advice... Dado sets will give you tearout no matter what you do the majority of DIY enthusiasts jigsaw.

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