Sheet goods - getting off the floor

[Duct Tape]

Ever since I sold my Felder slider I’ve been breaking down sheet goods with a track saw on the shop floor, with the plywood on top of a piece of foam insulation.

This has two drawbacks. One, it’s on the floor. At 67 this is getting old. Two, there’s no obvious way to clamp if I want more than just relying on the track to not slide. It seems to me that to use a clamp, you need the workpiece elevated off the ground higher than any of the available Festool or third party clamp heights, with an overhanging edge.

I see many pics of people working directly on their MFT or other tables, such as the pic from the TSO web site below.

How is this done without cutting into the workbench top? I have several benches, outfeed, and assembly tables I’ve built but prefer to keep the surfaces clean. I suppose I could always use a sacrificial piece or foam underneath. A couple of sawhorses is an option but I’m cutting expensive hydrotek marine ply and need the 4x8’ piece to not flex or move until cut is complete. Ripping down the middle of a sheet with the cut line off to the side of the bench top has the same support issues.

Appreciate any advice. Thanks.

 

[P_K]

You might want to look into the STM 1800. https://www.festool.com/accessory/saws/underframes-and-work-benches/work-benches/205183---stm-1800

 

[bwehman]

I mean this respectfully, but changing my mindset to just be OK with the idea of work table tops being sacrificial really changed the way I approached woodworking. Very liberating perspective shift.

 

[Packard]

I have metal saw horses that have brackets on each end of the cross pieces to hold 2” x 4” studs. I set up the saw horses, add the 2” x 4” x 8’ studs, and then drop a wide foam sheet on the studs.

For extra support, I added stud hanger brackets that allow short pieces of 2” x 4” studs to connect the two 8 footers. I will try to post an image later.

The metal saw horses are fairly heavy, but fold to a very compact size. The rest of the components are light and store easily. Best of all, I am cutting at workbench height.

The whole setup cost a little over $100.00 back when I set it up. Best of all, I add a. Roller stand and I can roll the sheets out of my van directly onto the setup and start cutting. No lifting of the full sheets at all. Hopefully, when you sold your table saw, you kept your roller stands.

 

[tjbnwi]

Place the foam on the table as you do for the floor.

 

[rmhinden]

I also use foam to protect my workbench top. I got an exercise mat at Home Depot years ago like this: https://a.co/d/akqPzfW There are many choices.

Easy to take apart and store when not being used.

Bob

 

[Sparktrician]

I made a grid of cheap 2x materials from the borg and set it on a couple of sawhorses as needed. It also comes in handy when I need to spray various materials.

 

[hdv]

I don't like sawing in foam. I don't want nasty stuff to get into the air, where I can breathe it in. Instead I have been using Veritas Platform Saddles and a few straight pieces of lumber. I really like those.

 

[leakyroof]

Place the foam on the table as you do for the floor.

This ^^^- lightweight to lift onto your table as well.

 

[PaulMarcel]

The STM-1800 is ideal for you. Hooks on the side to flip the board up on top, smooth wheels, and a sacrificial top so you just cut there. It accordions out easily so you don't have to have it full-size. I use mine far more than I expected

 

[peter halle]

I mean this respectfully, but changing my mindset to just be OK with the idea of work table tops being sacrificial really changed the way I approached woodworking. Very liberating perspective shift.

Personally I'll agree with you. At one point I was using foam and doing everything to keep from cutting into my top and later also the wooden strips on the STM that it became for me distracting. Once the first cut was made it made a difference. Similar to getting that first scratch on a purely work vehicle.
Peter

 

[Jim_in_PA]

The STM-1800 is ideal for you. Hooks on the side to flip the board up on top, smooth wheels, and a sacrificial top so you just cut there. It accordions out easily so you don't have to have it full-size. I use mine far more than I expected

I agree and am actually considering as an option for my own shop because it not only supports the workpiece, it also lifts it up in a manageable way. I'm 68 headed north of there and heavy 18mm sheets are less and less fun to lift, both for cutting on my current cutting table and also getting them onto my CNC machine.

 

[Packard]

I agree and am actually considering as an option for my own shop because it not only supports the workpiece, it also lifts it up in a manageable way. I'm 68 headed north of there and heavy 18mm sheets are less and less fun to lift, both for cutting on my current cutting table and also getting them onto my CNC machine.

How do you transport your plywood? I originally planned on using the track saw just for breaking down sheets to manageable size to carry to my basement shop.

I have since found that I can cut to finished sizes with sufficient accuracy for cabinet work. Now, about 90% of my cutting is done on the track saw on my driveway. I am carrying 12” wide x 30” pieces or 20” wide by 30” pieces max. Though for shelves, I am carrying 11” x 72” planks.

If carrying boards is an issue (I’m 78, so I can commiserate) then think through your work flow. It might dictate your purchases.

 

[Distinctive Interiors]

I have an STM 1800 and although it wasnt cheap to buy, it has paid for itself many times over.
Everytime I use it, which is often, my back thanks me, especially as the majority of the sheets that I break down are 2800mm x 2070mm x 18/19mm thick.
I couldn't pick a full sheet up by hand even if I wanted to, as it's too heavy.
One of the best investments I've ever made.

Edit. I'm 63 by the way....

 

[Dog Island Offcuts]

I also wanted to get my track saw cutting off the floor, but I didn't want a full-sized table taking up space in the shop. So I made a folding lattice breakdown table with a sacrificial top edge. Sometimes I use it for assembling stuff, but usually it stays in the back room next to the wood rack until I need it. The sacrificial top will probably outlast me. I can clamp material to the table. And when I need to secure the track saw guide, I have room to clamp the guide to the wood being cut.

 

[peter halle]

I also wanted to get my track saw cutting off the floor, but I didn't want a full-sized table taking up space in the shop. So I made a folding lattice breakdown table with a sacrificial top edge. Sometimes I use it for assembling stuff, but usually it stays in the back room next to the wood rack until I need it. The sacrificial top will probably outlast me. I can clamp material to the table. And when I need to secure the track saw guide, I have room to clamp the guide to the wood being cut.

View attachment 379547

Very nice table!

Peter

 

[luvmytoolz]

@Dog Island Offcuts That's a brilliant solution!

 

[Duct Tape]

Thank you everyone. A lot of great info.

 

[tjbnwi]

I don't like sawing in foam. I don't want nasty stuff to get into the air, where I can breathe it in. Instead I have been using Veritas Platform Saddles and a few straight pieces of lumber. I really like those.

With dust extraction I don’t experience foam in the air. With the foam being lighter and under the material being cut my guess is the foam dust is well captured.

Tom

 

[Jim_in_PA]

How do you transport your plywood? I originally planned on using the track saw just for breaking down sheets to manageable size to carry to my basement shop.

Small 5x8 utility trailer to my shop building door, whether I buy locally or have it delivered because there's no driveway to the shop building. I use my Kubota tractor to move the trailer from the front of the house/driveway accordingly. From there, I move it into a vertical storage rack unless I'm using it immediately. This is a very different situation than you have with a basement shop where breaking down makes sense, but it also requires you to pre-plan before you buy the material for obvious reasons. I tend to buy more material than needed for a single project to reduce the logistics of getting and moving material.