Circular saws take steps ahead

Greater attention to power, weight and usability makes newer models easier to use and more productive.

Few tools have as wide an acceptance and user happiness as circular saws. Like a hammer or screwdriver, it’s hard to improve upon a design that was nearly perfect when it was introduced.

“There are few tools with as high a satisfaction rating from end-users. It is a straightforward product that does one thing; cuts straight lines,” says Randall Coe, director of product development at Bosch Power Tools and Accessories.

Depending on where you live in the country and the type of work you do, you will fall into one of two camps when it comes to circular saws. You will either be a fan of a worm-drive or hypoid gear saw, or a sidewinder or direct-drive saw, says Coe.

“It’s often a matter of how you were taught to cut with a circular saw. West Coast framers are convinced the worm-drive saw is the best design. Typically the worm-drive saw is popular west of the Mississippi; sidewinder or direct-drive saws are more popular east of the Mississippi. It’s an odd product in that there are such distinct preferences that can be labeled geographically. It all depends on which saw you were taught to cut with,” Coe says.

Worm-drive and hypoid-gear saws
Worm-drive and hypoid-gear saws have the motor’s drive parallel to the blade. Typically, the trigger switch and handle are positioned on the back of the unit. They are heavier than in-line units.

“Users cut differently with these saws than a direct-drive saw,” says Vince Caito, marketing communications manager at Makita. “Users rely on the weight of the saw and gravity to make most of the cut. For framers, it’s a very fast way to cut studs,” he says.

Typically, these tools weigh around 15 lbs. and have a reputation for long life. “Worm-drive saws have a very durable power train. They are not the lightest saws or the prettiest saws but they are durable. For example, a worm-drive saw will cut concrete four times longer than the alternative,” Coe says.

In-line saws
In-line saws have the motor mounted perpendicular to the blade and directly drive the blade. The handles are typically mounted over the top of the unit, however Milwaukee offers the Tilt-Lok model where the handle can adjust from the conventional top position to a rear position. The operator can adjust the handle for the job at hand, says Tom Parpart, woodworking product manager at Milwaukee Electric Tool. “This allows the handle to be positioned like a worm-drive saw so the operator can push the saw through work such as making long cuts on plywood sheets. It puts your hand in a more natural working position,” he says.

Lighter saw weight is important to all saw users, and manufacturers have been working to take weight out of these saws without losing durability, says Mike McDowell, DeWalt circular saw product manager. “We are seeing more magnesium being used in saws. DeWalt’s saw uses cast magnesium for the upper and lower guards. One of our units has a composite fiberglass shoe that is light, yet can survive a one-story drop without breaking. Any light-weight material used in these saws must take knocks and not bend,” McDowell says.

Direct-drive saws weigh up to five lb. less than worm-drive or hypoid saws, and users familiar with these saws cite that as an overall advantage when they compare the two saw types.

“Users must look at the weight and the overall feel of the saw in their hands. If it’s comfortable, look for the highest power saw for the dollar. From there, consider other saw features,” says McDowell.

Blade-left or blade-right?
Worm- or hypoid-drive saws have a blade-left configuration to attain a better balance, says Dave Hall, senior product line manager for construction tools at Porter-Cable. “Blade-right saw designs have primarily been on direct-drive saws. However, there are models of direct-drive saws that offer blade-left configurations. In part it has been an attempt to attract worm-drive users to direct-drive saws but it has really grown because certain users find it more comfortable. For a right-handed person, a blade-left saw puts the cut line right under the right eye so it’s easier to see the saw line. They have become very popular, with our circular saw sales split about 50-50 between blade-left and blade-right units.”

Creature comforts
“We have watched workers on construction sites become more specialized in what they do. Each worker may have three or four specific jobs they do and they often do one of those jobs all day. The complexion of the workers and the jobs are changing, so tools must better fit their needs,” says Hall.

If a worker uses a saw all day, creature comforts help reduce fatigue, and that’s why there is a trend to soft- or cushion-grip handles, easy saw adjustments and lighter weight without sacrificing durability.

With the advent of magnesium, composites and aircraft-quality aluminum components of saws, new direct-drive saws weigh less than 10 lbs., much lighter than previous models. “Lighter saws that are well-balanced cause less user fatigue,” says Coe.

New models
A few manufacturers are coming out with new saws this spring that take a solid concept and address issues that affect user fatigue and downtime, says Hall.

“Our new MAG saw line addresses a common problem that affects downtime on the jobsite. When it comes time for blade changes, it’s rare that the wrench or blade key is handy. That’s why Porter-Cable has introduced the Quick-Change system where the blade nut has a flip-out lever so users can make wrench or key-free blade changes,” Hall says.

The units have cushion-grip handles and inch marking that zero out on the right or left side of the blade kerf for accurate cutting. The all-magnesium base has a quick-reference 45-degree angle on the back of it for quick marks for 45-degree cuts. They have an integrated dust exhaust port with 203-degree rotation that directs sawdust away and can be connected to a standard 1" O.D. vacuum hose. They have a maximum 50-degree bevel with a 45-degree positive stop and a cord clip that helps keep the cord away from the saw blade.

The new 7 1/4" saw line features a 15-amp motor and comes in four models: The 423 MAG blade-left and the 424 blade-left with electric brake and the 324 MAG blade-right and the 325 MAG blade-right with electric brake.

Bosch is also introducing a new circular saw line that is a new direction from its time-tested worm-drive design. “We started from scratch to develop a saw that addresses key reasons for downtime and user fatigue,” says Coe.

Bosch’s new CS10 and CS20 of 7 1/4" in-line saws offer some very handy features that make them durable and easier to use. “For example, the new saws are 20 percent lighter than previous models. They have magnesium upper and lower guards and a composite shoe that won’t bend or deform from jobsite abuse. It also includes a rafter angle chart on the composite base for easy reference, Coe says.

Both saws have positive bevel stops at 22.5- and 45-degree angles and can cut up to a 56-degree bevel. An integrated blower and improved motor placement offers great line of sight.

The CS20 model has a rafter hook that allows the user to hang it on a stud or sawhorse so it stays within easy reach after wood is repositioned. It also has the new Bosch Direct Connect cord system where the extension cord plugs directly into the saw. If the cord gets cut, the user can simply replace the plug and use the same cord, or grab another extension cord to continue working. “In the past, the tool would have needed to be sent out for service with a significant amount of time lost on the job,” Coe says.

Setting depth adjustment correctly for different wood thickness is easy with this saw. The depth adjustment is marked off to match the nominal wood sizes. The unit also features an anti-snag guard that helps reduce the guard catching on bevel cuts.

 “We have also done away with the conventional boxy carrying case. No one uses it, so we replaced it with a soft-sided carry bag that protects the saw yet stacks and transports well,” Coe says.

The saws also come with a C3 Dyanite Carbide blade that Bosch claims will stay sharp up to five times longer than a standard carbide blade.

Published in the March 2004 issue of Contractor Tools and Supplies magazine.

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