Ideas for cutting random shaped plywood panels

[tomsalwasser]

Greetings oh wizards of the wood. I think I have an answer to my problem but I have no doubt you have more ideas for me.

I need to cut a couple of plywood panels, 1/4" walnut veneered mdf, into random non square shapes to veneer some of the larger lower cabinet boxes in my kitchen. The cabinets and walls in my kitchen are no longer perfectly square, if they every were. The panels are cut to rough size right now, 24" x 36". I tried to trim them to the random shapes on my table saw but they are too big to use the miter gage or sled like I did with the much smaller cabinet uppers. I can't use a plane because they are mdf panels. I don't want to butcher them with a hand saw. I have a clamping edge guide I could use with my circle saw but managing the cut line offset is a real hassle. I need the cuts to be clean, straight and dead on, whatever direction they go.

I think now is the time to purchase a track saw. This seems like it would work well. The problem is cost. The Festool track saw I really want is $640 everywhere. Festool does not allow discounts. Dewalt has one that's a little cheaper, but if I'm going to pay $500 I'd probably go all the way and get the one I really want for a little more. I can get a Shopfox track saw on Amazon for $200, the track costs extra, but I worry about the quality.

Any other ideas? Any way I could use my Shopsmith for this? Thanks for your thoughts! I'll be away from the computer for a while but I will check back later.

[dusty]

A track saw might work but this sounds to me like a job for your hand held router.

I did this quite a bit when cutting panels for the RV. I use the edge of my work bench as the straight edge. With the work piece clamped (or secured with two sided tape) to the work bench (desired cut line aligned with edge of bench), a router equipped with a bearing guided straight router bit does the job.

I have recently become very fussy about two edges of my work bench because of this. I actually trimmed down the size of my bench top in order to get two smooth, straight reference edges. I used 3/8" veneered paneling for the RV and this has worked great.

To cut paneling longer than my work bench and have to relocate the work piece after making a partial cut but except for time delays that has not been an issue.

[Gene Howe]

A good serviceable track saw is so easy to make.
Here is a thread with one I made. My contribution is about 8 posts down.

http://www.shopsmith.com/ss_forum/viewt ... aw#p158770

[roy_okc]

Tom,

EurekaZone has a small sale right now on their 72" kit for $199; however, that is an odd size for a starter track -- too short for 8' ripping and much longer than needed for 4' cross cutting. A better size in general, IMHO, would be the 54" kit, $180. Just attach your circular saw onto the included saw base.

http://www.eurekazone.com/category_s/2031.htm

[benush26]

Hey Tom,
Though I think that buying new tools is very fun! , and a track saw or something similar has been on my radar lately, I have to go with Dusty on this. Especially with a material at 1/4".

I have been helping a friend who is using 1/2" walnut veneer on MDF. He has been making the cuts based on the grain/style in the veneer rather than just following the factory cuts. He bought both afour foot and eight foot straight edge which we set in place, then on the side away from the cut, butt up a few pieces of MDF using carpet tape to keep the straight edge from flexing. We do use clamps however clamps alone on the ends were too prone to allowing slipping and when we tried double stick on the bottom of the straight edges, it held too well, resulting in the need to buy another straight edge with no human made extra BEND...

A nice Amana carbide router bit has made many feet of excellent cuts. We did buy a base plate with a square face to always run along the straight edge so the bit is always the same distance.

Cost of the straight edges (including the extra replacement ! , yes, I'm the one who bent it), router bit and extra base plate was still under $85

Just a thought (actually Dusty's albeit with a few slight mods)

If you DO buy the Festool please post pictures so I can drool... It helps when I clean off the screen!

Be well,
Ben

[dusty]

I have had the pleasure of using a Festool. It was an extra special pleasure because I did not pay for it. There is no doubt that the Festools are all something special but I just can not justify the cost. Maybe, if I was twenty years younger but as it is there is just not enough time to achieve payback.

[tomsalwasser]

Thanks guys. Excellent answers, well worth the price of admission. Oh wait, this place is free? Well then your answers are priceless. Thank you!

A router and straight bit were not even on my radar. The only router I own is attached to the underside of a table. I use it to round over edges. I do not use a router otherwise. I think this is a fantastic idea that is pulling me in that direction. Dusty I'm sure every panel needed such treatment in your RV so you know exactly what I'm talking about. Ben I think I see just how you did the procedure but I sure would love a video. I really enjoyed seeing the shop built track saw and the standard circular saw track kits are up to the task too.

I was gone all day yesterday and when I got home my wife pointed out another track saw review article: http://www.woodworkersjournal.com/track-saw-review/

Still not sure exactly what I'm going to do but I'm much better informed now than I was 24 hours ago. Breaking down sheet goods is always a problem for me so I know I would get lots of use out of a track saw even after my kitchen project is over. I'll keep you posted!