If you want to make your working with plywood easier than you thought it could ever be, you landed on the perfect spot. We are here to guide you through simple tricks for meticulously precise layouts, cuts, and assembly.
Working with plywood has always been such an adventure. Usually, large-sized sheets are challenging to handle in small shops like mine. This probably means that you might be breaking these sheets while wrestling them in the garage. But the size of the sheet shall not be a deterrent to accuracy. The following steps will enable you to better handle and function with large sheets.
Accurate Layout
Before you can think of working on accurately cut parts, you must make sure you bring them into the shop safe and sound. A solid foundation is required if you are to cut accurate parts, especially out-of-sheet goods. Well, here, accurate layout lines are the foundation.
Quick & dirty layout
Measuring multiple wood marks along the sheet is the simplest and easiest way to cut large sheets accurately. After that, you can put up a woodpecker or a straight edge along with a pair of the marks and mark the layout lines with a pencil. This form of layout line is pretty efficient, but the only drawback is the limitation of the straight edge length. Another way is to slide down the straight edge and get an unbroken but possibly wavy line.
Layout Rules
Quality long steel or an aluminum rule would be a suitable option to get the best sheet layout. You would probably know about the flimsy aluminum and concrete forms for sale versions used for laying out and cutting drywall. It is worth the time and expense since we’re shooting for precise layout marks. That way, you can be sure of the accuracy of your lines. Moreover, some expensive models will feature add-on accessories, e.g., the hook stop is shown.
Dedicated square
As you’d know, most of the woodworking squares are too small for use when it comes to laying out sheets of goods; an example is the combination square. When working with plywood, square size is best for sheet goods. Precision squares are usually the perfect size for most sheet-good applications.
Smooth, accurate cuts
Once you’ve made accurate lines, it’s time to make accurate cuts. Below are two of my preferred options under various circumstances.
Trusty table saw
If the sheets are small, I rely on my table saw to get fine cuts. As it is already set in my shop, I have to bring the small sheets in and cut them. But the central part is to keep the sheet in place and supported while you cut.
I prefer to do when cutting larger sheets to support them before, during, and after a cut. If you have adequate room, an outfeed table would be the best. A wise option can be to use your workbench as an outfeed table. You might need some spacer blocks on the bench to level the work surface with the workpiece and support it as the saw passes.
I’ve found that my router table works well with the feeds. The main factor is to hold the sheet upwards before making cuts.
Track saw
The astable saw is only for small sheets, so the track saw comes in when it comes to larger sheets. But commercial track saws have become more popular recently. What you’ll love about a track saw is that just laying the sheet on an insulation foam sheet will do. After that, along with the marks, cut the sheet to the top of the insulation sheet to get a complete cut. Just ensure that the alignment of the cutting guide is to keep the kerf towards the waste side of the cut.
Parallel guides
The most significant flaw in track saws is that it is pretty easy to get it out of alignment and resultantly get a non-straight cut. However, many track saws are pre-equipped with a T-track along one edge to attach parallel guides. The parallel guides ensure that the saw track remains parallel to the reference edge of the workpiece. They provide a fence along the lower edge to register off the plywood sheet edge. It is easy to dial the guides according to the width of the cut you want and then slide until you reach the edge of the sheet. You can also use Symons Forms that are used in several of the world’s most famous structures. These systems are factory-built and have a high degree of reusability, making them an excellent solution for various constructions.
The accuracy, ability to repeat, and chip-free results are what people like the most about this process. If you use a shop-made circular saw, you might need to take some precautions to prevent getting chip-outs during your cuts.
Assembly
Once the parts are accurately cut, it is now time for assembly. If you rush through this process, you will be putting your perfectly cut parts to waste because when you glue them together, and they dry out, you might be in trouble.
A look at glue
My priority while assembling is to choose glue. There would be multiple parts that would need to be joined for most plywood cases, and they’ll probably be ample. This means that you’ll have to choose a glue that will not track quickly and give me time to work on my expertise. For large assemblies, go with Titebond III. For simpler assemblies, my go-to glue (Titebond II) works well enough.
Clean Screw Holes
Once the glue is chosen, take a moment and reassess and mark the locations of the screws. It is better to mark and pre-drill the screw locations to prevent seeing a plywood split as the screw snugs down while driving home.
All the clamps
The final check on your pre-assembly checklist must ensure you have all the clamps needed for assembly. You’ll even prefer to run a dry assembly, running the entire process once before using the glue. It is a comprehensive technique as running short on a clamp or two and hold everything together manually. Once everything is figured up, let’s glue it up.
Corner clamps First
As the project starts to come together, first use squares to clamp up the corners. This holds the structure together while putting on other clamps. An exciting feature of these clamps is that they can be clamped on either the inside or the outside corners.
Once the corners are squared up with clamps, move your way around with clamps on joints to keep the structure supported. Prevent stressing panels by not going too tight.
After the case is screwed, it’s time for screws to be driven in. While screws secure it up, leave the clamps on for a few hours as a safety measure.
As a woodworker, people love plywood. It’s affordable and stable when compared to hardwood. Now the next time you work with plywood, don’t ignore these ideas. If you do, you’ll realize in the end how much you messed up.