How To Cut Plywood With A Hand Saw

Plywood is a durable and affordable material that woodworkers use in different projects. It offers a rustic yet attractive look and you can use it in a range of applications. However, these incredible characteristics won’t be of any use if you don’t know how to cut and transform plywood into desired shapes.

This article discusses the easy way you can use to cut plywood with a hand saw by avoiding splitters. It’ll come in handy if you don’t have motorized tools such as a circular saw to cut plywood properly.

How To Cut Plywood with A Hand Saw

If done correctly, a hand saw can easily cut plywood neat and clean. Use the following method carefully if you want to achieve the best results.

Supplies You’ll Need

• Hand saw
• Plywood
• Dust mask
• Pair of gloves
• Eyeglasses
• Marker or pencil
• Measuring tape

Step 1: Choose Right Hand Saw

Whether you’re a woodworker, DIY enthusiast, or a professional tradesman, you need to use a sturdy and sharp hand saw. It’s a great tool that you can use for both outdoor and indoor projects. The first step to cutting plywood is to choose the right product based on the following qualities.

TPI Configuration

Choose a sharp hand saw blade that comes with a 4 to 7 TPI (Teeth Per Inch) configuration. A lower TPI configuration than this will allow you to carry out the process faster but your plywood will have rougher edges.

Size

A handsaw with a short panel comes with a 12- to 20-inch length. It’s a suitable size for most projects. You can go with longer blades if you’re cutting plywood for a cabinet-making project.

Hand Saw Types and Purposes

You can choose any of the following hand saws depending upon your woodworking project along with the cut types you need to make.

• Coping Saw: This hand saw comes with a u-shaped body and thin blade and it’s most commonly used for cutting joints and fine woodworking. The best coping saws allow for precise cuts in tight work spaces.
• Backsaw: You can use a backsaw for both soft and hard types of plywood. This larger saw offers a neat finish and precise cuts.
• Crosscut Saw: It’s a long hand saw with 24 inches of length. It comes with a broader blade, a knife-like beveled edge, and teeth angles straight up. It takes longer to cut plywood but offers smoother cuts.
• Rip Saw: This hand saw comes with 26 inches of length. It offers rough edges as it has angled teeth that are not beveled.

Step 2: Ensure Safety

The second step is to ensure your safety. It goes without saying that working with wood is messier than dealing with aluminum and steel. Cutting wood creates a lot of dust that can be harmful to your health if inhaled.

You can also get injured while using a handsaw, although they’re easy to use. Additionally, small wood particles flying around can also get inside your eyes.

That’s why it’s important to wear a high-quality dust mask, eyeglasses, and cut-resistance gloves to ensure your safety. These safety measures are recommended by the Occupational Safety and Health Administration, especially when you’re involved in woodworking.

Choose a place for your plywood cutting project that’s free of all distractions. Make sure your kids and pets are not around while you’re cutting plywood with a hand saw.

Step 3: Measure Cut

Take measurements carefully before you start the plywood cutting process. Use a measuring tape and a marker or pencil to mark the plywood surface where you want to make the cuts.

You don’t want to stop the cutting process to make sure whether the length or width of the plywood piece is right or not.

Cross cuts are easier to make, and would typically be done at scale with a table saw. However, you can make the hand cut more accurate by using a guide fence.

Step 4: Create Small Notch

Once you have marked your plywood, secure the plywood on a flat surface so it doesn’t move during the cutting process. Start by making a small notch in the wood.

Place your hand saw’s blade over the board where you want to make the cut and move the saw gently back and forth without putting pressure.

It’ll make a small cut or notch into the plywood. You can also use your thumb knuckle for precision but be extra careful even if you’re wearing gloves.

Plywood has a very thin and delicate build and cutting it with the “right” angle is critically important to get precise and clean results. Use the hand saw almost horizontally because placing it vertically can damage your board.  

Step 5: Finish Cut

Once the notch or the small cut is visible, start using complete strokes. Focus on your hand movement and the plywood and continue the cutting process gently without applying too much force.

Make sure your forearms and shoulder are on the same line while you’re making strokes. Not only will it help you control the hand saw efficiently but it’ll also allow you to make straighter cuts.

Twist the handle of the hand saw slightly if you notice that the blade is going off track. Bracing the cutoff end is also important. You don’t want it to fall on the ground just to get damaged.

Once you’re about to reach the end of the cut, use your free hand to hold the cutoff part to keep it from free falling. At this stage, you can also make vertical yet short strokes to accelerate the cutting process.

Repeat the same process to cut as many plywood pieces as you want using a hand saw.

You can stain your plywood and add a wood finisher to it.

Tips to Use a Hand Saw to Cut Plywood Without Splintering

Splintering is basically the rough and uneven edges that usually happen if you don’t use the right steps to cut the plywood. Not only does it look bad but it also decreases the quality of your entire project. Keep the following points in mind if you want to avoid tear-outs and splintering with your plywood.

• Always start with a sharp blade and never use a dull or damaged one.
• Make sure to hair isn’t dangling near the workpiece, secure loose clothing, and remove jewelry before starting the cutting project.
• Cutting plywood on the push motion is always better than cutting it on the pull motion.
• Don’t put extra force while making strokes and align your forearm and shoulder for clean and straight cuts.
• Use a measuring tape to mark the plywood and double-check your measurements before starting the cutting process.
• You don’t want to cut the plywood vertically, especially while you’re making the notch. Get as horizontal as possible and make the strokes gently.

FAQs

Final Words

A hand saw is an excellent tool to cut plywood. It allows you to make accurate cuts and if you follow the right process, you can also avoid tear-outs and splintering. Make sure that you choose the right hand saw that comes with a 4 to 7 TPI configuration for the desired results.