Circular saws keep making the cut

Experts share how to rip through cutting jobs with these tried-and-true saws

Whether you are cross-cutting or ripping, it’s likely a circular saw is right in the middle of the job. These tried-and-true tools have earned a respectable spot on the jobsite, but that doesn’t stop power tool manufacturers from examining how users put these tools to work and offer advice and improvements that make the job faster, easier and safer.

Circular saws are dominated by two designs – worm-drive or sidewinder. Worm-drive units sport motors that run perpendicular to the blade, powering it through – you guessed it – a worm or hypoid drive transmission. They are heavier saws than sidewinders, and devotees say they have the torque and the right weight to plow through any cutting task. Sidewinder saws are driven through spur or helical gears.

Which type of saw is better? That depends where you grew up or learned how to use a circular saw.

“Circular saw preference is a regional phenomenon. West Coast contractors prefer worm-drive saws and Midwest and East Coast contractors tend to prefer sidewinders. The worm-drive saws are heavier and have higher torque. They have a greater feeling of power, but it’s mostly perception because both types of saws cut equally fast and well,” says Scott Teson, Milwaukee Electric Tool product manager.

While worm-drive saws can tip the scales at 16 lbs., you’ll find sidewinder units that weigh as much as 5 lbs. less.

A better fit
As power tool companies upgrade their saw lines, they are making them easier to use and less fatiguing. “You’re now seeing improved ergonomics that offer an overall better fit to the hand, and magnesium/aluminum base plates for lighter weight and durability. You’ll also see on-board blade wrench storage on many models,” says Rick Bush, Festool, USA. “Magnesium bases are the most common thread across new saws.”

Some models feature a composite shoe, which maintains light weight but can take jobsite abuse. “The composite shoe on the DeWalt DW369 CSK is built to take a one-story drop. While the shoe may flex on impact, it will return back to its original shape and flatness,” says Jon Bigden, DeWalt corded circular saw product manager.

Today’s saws offer improved blade visibility and guarding. Most can feed into the workpiece without hanging up, especially during bevel cuts. That eliminates the temptation to pin back the blade guard, which creates a hazard.

Blade changes are getting simpler as manufacturers are finding ways to carry blade/allen wrenches right on the saw. Others are making it easier to lock the blade for changes. For example, Festool upgraded its circular saws with its FastFix system which locks out the switch and locks the saw in an optimum position to expose the arbor.

Cordless gets more mainstream
The advent of lithium-ion (Li-ion) technology has increased saw runtime and power, experts report.

Cordless saw manufacturers are offering models from 18 to 36 volts. The larger units rival corded saws in power, and longer runtimes make them viable production cutting tools.

“Cordless circular saws provide users with freedom on the jobsite and are particularly useful for remote or hard-to-reach jobs such as cutting rafter tails. Users say they like 18-volt cordless saws for this type of job,” says Jim Watson, DeWalt cordless circular saw product manager.

“DeWalt offers 18-, 28- and 36-volt units. The 18- and 28-volt units have 6.5" blades and can make all types of 2x cuts. The 36-volt unit has a 7 1/4" blade and really goes after the corded saw market and jobs. It has enhanced features such as bevel detents and additional power to turn the 7 1/4" blade.”

“The big buzz is still lithium-ion power. Bosch has its 36-volt Litheon system which has blown people away with its performance and we’ve adapted it to our coming 18-volt lineup. We get less weight without sacrificing cutting rate or run time against other 18-volt models,” says Edwin Bender, Bosch group product manager for cordless products.

The Bosch 36-volt saw can be used with a Fatpack battery and has the power and runtime needed for framing applications.

“If the user does not need quite so much runtime or power, he can take advantage of our flexible power system (FPS) and use the 36-volt Slimpack that weighs the same as an 18-volt Li-ion pack and still get more performance than any other 18-volt circular saw,” Bender says.

“We will launch the 18-volt battery and tool this fall. It will complement our Ni-Cd version that offers solid performance for everyday tasks like cross-cutting 2x at a competitive price point. The 18-volt Li-ion tool will improve on the performance of the Ni-Cd tool and will offer substantial weight savings. We’re also finding the Li-ion version ideal for general contractor tasks such as cutting OSB and 2x material,” he says.

Use tips
The experts agree the first step to safe, productive circular saw use is to read and follow the instruction manual and on-tool warnings. That includes proper eye, respiratory and hearing protection and checking the guard frequently for proper operation. Maintaining proper hand and body positioning and adequate material support will also assure safe and productive use.

Second, the experts recommend using the right extension cord. “Use the correct gauge of extension cord with the saw,” says Teson. Across all tools, the table above shows the gauge of wire needed for different amp ratings, based on cord length.”

Third, make sure the blade matches the job and is clean. “We often see one blade on circular saws being used for everything, and it’s usually a dull one. A blade can bog down from pitch and resin buildup. This makes the kerf wider, which causes more load on the motor. It also greatly reduces cut quality because the sharp tooth is buried in all that build up,” he says.

Published in the July/August 2008 issue of Contractor Tools and Supplies magazine.

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