cutting large panels

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Forum topic by JeffS100 posted 09-04-2020 01:31 PM 283 views 0 times favorited 3 replies Add to Favorites Watch
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1 post in 286 days

09-04-2020 01:31 PM

I am making 8 built in bookshelves for a family room that are 60” tall. I have a 32 in table saw and need to find an accurate way to cut 16 pieces of plywood. I was thinking of using a cross cut sled but I think the pieces will be too big to cut safety. My other thought was to cut one piece with a circular saw (clear the edge with a straight bit in the router), then use the first piece and a flush trimming bit to cut the remaining pieces. Thoughts?

3 replies so far

View northwoodsman's profile


584 posts in 4863 days

#1 posted 09-04-2020 01:48 PM

Perfect excuse to buy a track saw – splinter free cuts! The router method would work also.

-- NorthWoodsMan

View DrTebi's profile


402 posts in 4384 days

#2 posted 09-04-2020 03:44 PM

I have just been in the same situation. I ended up cutting all plywood slightly oversized with a skill saw with a guide, and then cut each piece to exact size on the table saw with a panel sled. Here is an example of one:

Mine actually has an aluminum angle that holds the fence; it’s mounted with four machine screws into t-nuts. The holes in the aluminum piece are a bit oversized, which allows me to realign the fence when necessary.

This panel sled works great, although it depends a bit on how wide your panels are. On my SawStop PCS I can cut 24” wide panels fairly easily, wider than that can be tricky.

Doing the same (cutting slightly oversized panels) and cleaning up with a guided router should be a good option as well, but will be more elaborate, since you need to re-clamp the guide perfectly square every time.

Good luck!

View SMP's profile


4148 posts in 1023 days

#3 posted 09-04-2020 04:01 PM

Just get a roller outfeed stand.

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