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Default How to make plunge cut in MDF sheet?

I have a requirement to cut a rectangle from a larger piece of 18mm
MDF sheet. The dimensions of the 'hole' are approx 800mm x 400mm

I need the cut edges to be true, ie with no 'wavy cuts'. I would also
like to reuse the 'cut out' material to form a sort of 'door'.

Before doing it in anger, I have experimented using both a jigsaw
(with the expected result of a 'wavy cut') and the Bosch 'MultiMaster
clone' tool (with slightly better, if fairly slow, results). Neither
of these is satisfactory.

Any suggestions for cutting an accurate rectangle, please?

I don't really want to fork out many £££ x 100 for new power tools,
but am willing to consider it if it's something I will use again. I
do have a handheld circular saw, but no table saw - and while I've
looked at saws with a slide I haven't seen any that slide to the
dimensions I'm looking for - but I could easily have overlooked
something obvious.

I've thought of plunging a cut with the Bosch tool, then completing
the job with a hand saw - but I'm sure there must be a way with the
'right' power tool...

Many thanks in advance

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Default How to make plunge cut in MDF sheet?

Whichever method you use, you'll loose the thickness of the saw kerf
at least in the cut (and on each side of the cutout board). You could
batten the edges after making the cut, in which case you would have
the opportunity to clean up any irregularities.

As John says, plunge cut with a circular saw (riving knife, if there
is one, removed). Practice on a bit of scrap board first, and use a
guide for the cut (especially when starting plunge cuts). It isn't
really that skill demanding, more about having the nerve to do it.
Ensure the start and stop points allow the visible upper curve of the
blade to stop just short of your corners, leaving about an inch on the
underside.

To get tight, square corners with no overcut, you'll then have to
handsaw/jigsaw/multimaster the first and last inch (again with a
guide, unless your skill level is up to it).

It's possible to plunge cut with a jigsaw (very gently tipping back
from the front edge, whilst very slightly moving forward), but that is
somewhat skill demanding.

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Default How to make plunge cut in MDF sheet?

On Sun, 14 Oct 2007 02:12:40 +0000, Richard Perkin wrote:

I have a requirement to cut a rectangle from a larger piece of 18mm MDF
sheet. The dimensions of the 'hole' are approx 800mm x 400mm

I need the cut edges to be true, ie with no 'wavy cuts'. I would also like
to reuse the 'cut out' material to form a sort of 'door'.

Before doing it in anger, I have experimented using both a jigsaw (with
the expected result of a 'wavy cut') and the Bosch 'MultiMaster clone'
tool (with slightly better, if fairly slow, results). Neither of these is
satisfactory.

Any suggestions for cutting an accurate rectangle, please?

I don't really want to fork out many £££ x 100 for new power tools, but
am willing to consider it if it's something I will use again. I do have a
handheld circular saw, but no table saw - and while I've looked at saws
with a slide I haven't seen any that slide to the dimensions I'm looking
for - but I could easily have overlooked something obvious.

I've thought of plunging a cut with the Bosch tool, then completing the
job with a hand saw - but I'm sure there must be a way with the 'right'
power tool...

Many thanks in advance


==================================
A pull saw will do this job if you're careful and take your time. This
type of saw is used at a low cutting angle and can be used to cut into a
solid board by carefully working on one line until a through cut is
achieved. A pull saw also has the advantage of probably the smallest
possible kerf.

http://www.diytools.co.uk/diy/Main/P...roductID=38194

or

http://tinyurl.com/2lv4nx

Cic.

--
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Using Ubuntu Linux
Windows shown the door
===================================

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Default How to make plunge cut in MDF sheet?

On 14 Oct 2007 02:12:40 GMT
Richard Perkin wrote:

I have a requirement to cut a rectangle from a larger piece of 18mm
MDF sheet. The dimensions of the 'hole' are approx 800mm x 400mm

I need the cut edges to be true, ie with no 'wavy cuts'. I would also
like to reuse the 'cut out' material to form a sort of 'door'.

Before doing it in anger, I have experimented using both a jigsaw
(with the expected result of a 'wavy cut') and the Bosch 'MultiMaster
clone' tool (with slightly better, if fairly slow, results). Neither
of these is satisfactory.

Any suggestions for cutting an accurate rectangle, please?

I don't really want to fork out many £££ x 100 for new power tools,
but am willing to consider it if it's something I will use again. I
do have a handheld circular saw, but no table saw - and while I've
looked at saws with a slide I haven't seen any that slide to the
dimensions I'm looking for - but I could easily have overlooked
something obvious.

I've thought of plunging a cut with the Bosch tool, then completing
the job with a hand saw - but I'm sure there must be a way with the
'right' power tool...

Many thanks in advance


Circular saw with guide batten would be my way. You need to take off
any riving knife, but the cut in MDF will not close up, so it's safe.

If you ARE going to buy a new tool, my advice is to buy a SMALL
circular saw. Although a large one has more oomph and can make bigger
cuts, accuracy with a circular saw is enhanced by lightness (unless
you are a weightlifter) - especially if you are reaching over a big
board. I have three saws, but only ever use the smallest one (It's a
American Porter-Cable used with a 110Volt transformer).

R.
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Default How to make plunge cut in MDF sheet?

On Oct 14, 3:12 pm, Richard Perkin wrote:
I have a requirement to cut a rectangle from a larger piece of 18mm
MDF sheet. The dimensions of the 'hole' are approx 800mm x 400mm


A biscuit joiner would be the safest and easiest way. The blade is
quite thick however.
Biscuit joiners are quite cheap these days, and you'll find all sorts
of uses for it.

http://en.wikipedia.org/wiki/Biscuit_joiner



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Default How to make plunge cut in MDF sheet?

On 2007-10-14 03:12:40 +0100, Richard Perkin said:

I have a requirement to cut a rectangle from a larger piece of 18mm
MDF sheet. The dimensions of the 'hole' are approx 800mm x 400mm

I need the cut edges to be true, ie with no 'wavy cuts'. I would also
like to reuse the 'cut out' material to form a sort of 'door'.

Before doing it in anger, I have experimented using both a jigsaw
(with the expected result of a 'wavy cut') and the Bosch 'MultiMaster
clone' tool (with slightly better, if fairly slow, results). Neither
of these is satisfactory.

Any suggestions for cutting an accurate rectangle, please?


Not with either of those for that kind of size.



I don't really want to fork out many £££ x 100 for new power tools,
but am willing to consider it if it's something I will use again. I
do have a handheld circular saw, but no table saw - and while I've
looked at saws with a slide I haven't seen any that slide to the
dimensions I'm looking for - but I could easily have overlooked
something obvious.

I've thought of plunging a cut with the Bosch tool, then completing
the job with a hand saw - but I'm sure there must be a way with the
'right' power tool...

Many thanks in advance


I've normally done this on a saw table by accurately positioning the
material and then raising the blade, stopping before the corners.

The nearest simulation for that would be to make sure that you can
fully support the material over more than just the cutting area first
and to use a circular saw. Bear in mind that once the centre panel is
removed, the surrounding sheet will have lost some rigidity so must be
well supported and flat. One way to do that is to lay a row of battens
of 50x25 spaced apart on a bench. The battens can be part sacrificed
so that the saw blade depth can be made a few mm more than the material
thickness.

Carefully measure the distance between the edge of the plate of the saw
and the edge of the blade and position a straight batten on the top
surface that distance from the line. You can safely remove the
riving knife from the saw in this application because the material
can't close the gap, provided that the sheet is properly supported.

The saw can now be carefully plunged. Keep in mind the shape of the
blade and stop before the ends. You can finish the last few mm with
a pull saw.

Using a dust mask with MDF cutting, especially with a circular saw is
important.


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Default How to make plunge cut in MDF sheet?

TheOldFellow wrote:


If you ARE going to buy a new tool, my advice is to buy a SMALL
circular saw. Although a large one has more oomph and can make bigger
cuts, accuracy with a circular saw is enhanced by lightness (unless
you are a weightlifter) - especially if you are reaching over a big
board. I have three saws, but only ever use the smallest one (It's a
American Porter-Cable used with a 110Volt transformer).



Oh good, its not just me who has that opinion then!


I searched high & low for a new 165mm circ saw - everyone wanted to sell me
a 190mm +. Settled on the Makita 5604. Still has a 54mm depth of cut which
is enough for me.

Completely agree, much better accuracy (and I was a weightlifter) :-)


--
Dave - The Medway Handyman
www.medwayhandyman.co.uk
01634 717930
07850 597257



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Default How to make plunge cut in MDF sheet?

On 2007-10-14 10:34:11 +0100, "The Medway Handyman"
said:

TheOldFellow wrote:


If you ARE going to buy a new tool, my advice is to buy a SMALL
circular saw. Although a large one has more oomph and can make bigger
cuts, accuracy with a circular saw is enhanced by lightness (unless
you are a weightlifter) - especially if you are reaching over a big
board. I have three saws, but only ever use the smallest one (It's a
American Porter-Cable used with a 110Volt transformer).



Oh good, its not just me who has that opinion then!


I searched high & low for a new 165mm circ saw - everyone wanted to sell me
a 190mm +. Settled on the Makita 5604. Still has a 54mm depth of cut which
is enough for me.


It is a shame. there are several makes of small saw in the U.S.,
although the PC one is the popular one.

There are also circular saws with worm drives for more torque, I
suppose. When you build houses all with wood, you need that.



Completely agree, much better accuracy (and I was a weightlifter) :-)


So why aren't you using your table saw up trees?


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Default How to make plunge cut in MDF sheet?

On Sun, 14 Oct 2007 09:03:49 +0100
Andy Hall wrote:


Using a dust mask with MDF cutting, especially with a circular saw is
important.


Damn good point. MDF dust is carcinogenic. And even the smallest
amount can bring on asthma in those susceptible (like me - I have to
use a full-head filtered-air thingy with MDF, and for a few days
afterwards, in my workshop).

R.

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Default How to make plunge cut in MDF sheet?

On Oct 14, 3:12 am, Richard Perkin wrote:

Before doing it in anger, I have experimented using both a jigsaw
(with the expected result of a 'wavy cut')


Hi,

What blade exactly did you try in the jigsaw?

cheers,
Pete.



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Default How to make plunge cut in MDF sheet?

Andy Hall wrote:


Completely agree, much better accuracy (and I was a weightlifter) :-)


So why aren't you using your table saw up trees?


Because I'm an ex weightlifter who isn't as daft as he looks :-)


--
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www.medwayhandyman.co.uk
01634 717930
07850 597257


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Default How to make plunge cut in MDF sheet?

On 2007-10-14 12:21:38 +0100, TheOldFellow said:

On Sun, 14 Oct 2007 09:03:49 +0100
Andy Hall wrote:


Using a dust mask with MDF cutting, especially with a circular saw is
important.


Damn good point. MDF dust is carcinogenic. And even the smallest
amount can bring on asthma in those susceptible (like me - I have to
use a full-head filtered-air thingy with MDF, and for a few days
afterwards, in my workshop).

R.


Have you thought about one of those box type powered dust filters? I
installed one of those and found it made a difference with materials
like teak; or do you think you are affected by vapour?

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