If you’ve ever tried to wrangle a full 4’ x 8’ sheet of plywood across a table saw by yourself, you know it’s a recipe for frustration—or worse, injury. At The Joinery, we’ve built a better way. Our large plywood bench and Festool track saw setup is designed to help you break down sheet goods accurately, safely, and with a whole lot less wrestling.
Setting Up for Success:
Before you make a single cut, here’s what to know:
• Use the Foam Board: Always lay a sheet of rigid foam insulation (we keep these handy under the plywood bench) under your plywood. This gives you full support across the surface and protects both the blade and the bench from accidental cuts.
• Orient Your Material Thoughtfully: Place your sheet with the best face down. The Festool track saw cuts on the upstroke, so the top will have cleaner edges. (But with the Festool’s splinter guard, tear-out is minimal on both sides.)
How to Use the Track Saw System:
1. Measure and Mark: Use a tape measure and a pencil to mark your cut line. Double-check your measurements—especially if you’re breaking down for cabinet parts or a furniture project.
2. Align the Track: Place the track directly on your cut line. The rubber edge of the track shows exactly where the saw will cut, so no offset is needed.
3. Secure the Track: For most cuts, the anti-slip grip on the bottom of the track is enough to hold it steady. But if you’re making a long rip or crosscut and need more stability, feel free to use the track clamps found in the cabinet under the bench.
4. Set the Depth: Adjust the saw’s cutting depth just slightly deeper than the plywood thickness—about 1/8” into the foam is perfect.
5. Make the Cut: Start the saw, let it come up to speed, then plunge and push through the cut at a steady pace. No need to force it—the saw does the work.
Handy Tips for Better Results:
• Check for Cords and Clutter: Make sure the power cord and vacuum hose are free to move with you as you cut. If they snag, your cut could wander.
• Use the Splinter Guard: If you’re cutting prefinished plywood or veneered panels, attach the Festool splinter guard insert for ultra-clean edges.
• Cut Big to Small: Start with a rough breakdown (cutting a 4×8 into manageable halves or quarters), then move to precise parts. It’s easier to get tight tolerances on smaller pieces.
• Label As You Go: It’s easy to get parts mixed up. Keep a pencil handy and mark each piece right after cutting.
Takeaway:
Learning to use a track saw properly is a game changer—especially for solo woodworkers or anyone working with large panels. With the right setup, like what we have at The Joinery, you can make clean, straight, safe cuts without ever lifting a full sheet onto a table saw.
Want to Learn More?
Checkout this great video and encourage members to use the track saw setup anytime. Not a member yet? Drop by for a tour or check out our intro videos online to see the tools in action.