Things to Consider.

Quality.

As with most power tools you usually get what you pay for. While every now and then, you might find a simple and inexpensive solution, rarely will you find a quality built tool at a discount price. How many times have you had to buy another tool, because you bought cheap instead of buying right? Let’s face it… a quality tool, built with quality materials will cost you more than you might want to pay initially. But, the good news is that the difference in what you paid up front should end up saving you more money in the long-run.

Good design, tight tolerances, use of quality materials, and uncompromising attention to detail will almost always create a tool that you can enjoy for many years. Saws should use top quality motor bearings to support the shaft and extend the useful service life of the tool. All moving parts should operate smoothly and should be adjusted easily. Tight tolerances and a smooth plunging action are good indicators of the quality of the tool. Other things to consider: How strong is the warranty? What do owners say about the power tools? Does the brand have a good reputation for manufacturing quality power tools? Does the company have a good service department in the unlikely event that there is a problem?

Straight Cuts.

When used with a quality guide rail, plunge cut saws are hard to beat for straight cuts. The guide strip on the edge of the rail acts as a zero clearance surface, and can be used to place the saw blade exactly on the cut line. Being able to maintain an accurate cut line is important regardless of the bevel angle of the saw. A good saw will use a pivoting mechanism to ensure that the cut line stays exactly on the edge of the guide rail regardless of the saw’s bevel angle setting.

The rails should be strong, light, and easy to adjust, and should come in a wide assortment of lengths with the ability to connect two or more to create custom lengths. Thin anti-slip bottom strips, and an easy way to clamp the rail down for added safety should be high priorities, as this will improve the cutting results significantly. Base plate adjustments should be easy to adjust, so that there is zero-play in the system, and tool-less adjustment knobs will make set-up easier.

Power.

Having a strong and reliable motor is important to getting good results. How much power is enough to do the job? The answer depends on the job. If you are going to rip 3 inch hard maple boards all day, then you should get a larger saw with extra power. If, on the other hand, you will be making a few cuts in ¾” plywood, you might prefer the comfort of a smaller and lighter saw. While power ratings can be confusing, make sure you are comparing the saws continuous power rating under load, as some manufactures may only list the saws peak power rating, which will not give an accurate measurement of the saws performance in use.

Once you have decided your power needs, look for a saw that offers Multiple Material Control (MMC). This feature will provide the following benefits and safety features for your protection: variable speed selection, constant speed control, soft-start, temperature monitoring, and motor overload protection. With MMC you can select the perfect speed for the material you are cutting. Matching the speed of the blade to the material being cut will greatly improve your cutting results.

Depth of Cut.

Selecting a saw with enough capacity to cut through the material you are working with is an important consideration. A saw with at least 1 ½” cut capacity should meet most end-users needs, as it should easily handle 5/4 stock or cut through two sheets of stacked ¾” plywood. However, if you will be cutting 8/4 or greater, a larger saw should be used with the trade-off coming in size and weight. Fine depth of cut adjustments will allow you to precisely position the blades depth of cut. Being able to cut through a piece of wood without damaging the under layer is valuable, so look for a saw that has an easy to use fine depth of cut control mechanism.

Splinter-Free, Burn-Free Cuts.

When working with expensive materials like cabinet grade veneered plywood or MDF, it is important to have cuts that leave splinter-free edges without burn marks to eliminate re-work or to minimize the amount of time spent cleaning up the cut line. Good results depend on a number of factors like tool design, choice of blade, saw blade speed, and material support. A high quality plunge saw and rail system will give consistent splinter-free cuts year after year.

Here are a few features that will help ensure high quality cuts. Look for easy tool-free saw to guide rail adjustments that ensure zero-play between the two. For the best quality cuts, use a system that has splinter guards on both sides of the blade (one on the rail, and one on the saw.) MMC electronics and a variable speed setting will ensure that a consistent and correct blade speed is used for the material being cut. A blade to base adjustment gives you the ability to adjust the blades position relative to the base, and riving knife.

[Tip: Adjusting the blade to be slightly toed-out at the back of the base plate will help eliminate potential burn marks. The difference from front to back should be less than the thickness of a business card. By making this adjustment, you can prevent the teeth at the back of the blade from coming in contact with the inside cut line.]

Anti-Kickback.

Anti-Kickback protection is important. One source of kickback is created when the teeth at the back of the blade come in contact with the material being cut, causing the material to ride up on the blade, forcing the material to be thrown in the direction that the blade is rotating. Well designed solutions can both protect against kickback, and offer additional advantages. The use of a riving knife can help prevent kickback by keeping the saw kerf open, and the top of the back teeth covered, which greatly reduces the potential for kickback. The riving knife should move with the blade to keep the distance, or gap, between the knife and the teeth constant over the entire range of cutting depths.

Another anti-kickback device is the adjustable limit stop. This device works to hold the back of the saw base against the rail during a plunge cut. By placing the stop on the guide rail instead of the base of the machine, the saw can be pushed forward unrestricted through the rest of the cut after the initial plunge cut has been made, and the saw can be easily removed from the rail at any point. An added benefit of this design is that two separate stops can be placed on the rail to create positive stops at both the beginning and end of cut making repeat cuts of exactly the same length both easy and fast.

The inclusion of a slip clutch on larger plunge cut saws is one of the most innovative features introduced to this class of saw. This design allows the blade to disengage with the arbor if the blade binds in the material being cut. This can help reduce potential injuries, and prevent damage to the saw, eliminating unnecessary repairs caused by burnt motor windings or damaged arbor shafts. (Note: Using blades that have not been tested and approved by the manufacturer can damage the saw, and will void the warranty.)

Dust Extraction.

When making any cut, a saw is going to generate a lot of sawdust. Fine dust that is ejected into the air can make you sneeze, cough, and experience other allergy-like symptoms. It’s small, lands on everything in sight, and gets inside your power tools. Experts agree that limiting our exposure is the best protection. Good dust extraction extends the life of your power tools by reducing dust-induced tool fatigue. It improves your accuracy by giving you a clearer view of your cut lines, and helps create a healthier environment. Dust extraction should not be an afterthought, and is should be included in the design of the tool.

Good dust extraction should capture more than 92% of the sawdust being created, and it should not hinder the user when making a cut. Features like 360 degree rotating dust ports, which allow you to adjust the hose exit to the left or right side of the cut, and guide rail deflectors that prevent the hose from binding on the end of the guide rail are all nice features to consider. Being able to use larger hoses and higher air flow (CFM) will improve dust extraction considerably.

Blades.

Professionals know that you need to match the design of the saw blade to the material being cut, and the operation being performed. Blades should be designed for cutting efficiency, long-life, and superior cutting results. Variable tooth spacing, laser expansion slots, large arbor holes, and properly tensioned blade blanks all reduce vibration and result in cleaner cuts.

For best results, use blades that incorporate fine-grain tungsten carbide tips, as they are robust, sharpen nicely, and wear well under the toughest conditions. Some manufacturers color code their blades to make choosing the right blade for the job easier. While a combination blade is useful for general work, don’t compromise by buying a saw with a limited selection of saw blades. Make sure that you can purchase blades for both ripping and cross-cutting in various materials including hardwoods, softwoods, plywood, melamine, and soft metals like aluminum. Owning a wide selection of blades will improve results and expand the capabilities of the saw.

Other Considerations.

A quality tool should be comfortable to use, and feel balanced in your hand. The use of soft grip materials, color coded switches and controls, and the use of tool-less adjustments combine to make the user experience much better. Detachable power cords can be convenient, as they allow you to disconnect from the power source at the saw instead of the receptacle. Antistatic hoses and attachments will reduce the amount of dust being distributed around the work area, and are considered safer by many users. Look for convenient time saving features like locking arbor spindles and one handed blade changes to make it faster and easier to switch to the proper blade when making different cuts.

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