A circular saw is one of the most versatile and useful tools in the shop. With a few tips, making a wide variety of cuts with a circular saw is both enjoyable and safe. Follow these suggestions, and you'll soon be able to make anything from a few custom-fitted shelves and building an entire house faster and with better quality.
The first thing to do before cutting is to set the saw at the proper blade depth. If the blade is set too deep, more of the blade is exposed, increasing the danger. Also, with a deep blade setting, the saw has more possibility of binding and kicking back. In addition to being safe, the circular saw cuts more efficiently with the proper blade depth setting.
To determine the correct blade depth, unplug the saw and place it alongside the material that you are cutting. Retract the blade guard. Loosen the knob or lever that adjusts the depth and move the saw's base until the blade extends from ¼ inch to ½ inch below the material. Tighten the adjusting knob or lever and you're all set to go.
Using a circular saw means that you have to be careful and thoughtful about what you are cutting and how you are using the saw. A serious danger is binding. This happens when the piece that you are cutting bends in towards the blade and causes the material to bind, causing a dangerous kickback. You should always make sure that the piece you are cutting is positioned so that the cutoff material is free to fall easily away from you.
Another potential for binding is when you are crosscutting plywood. The plywood has to be supported across the entire length. Failure to support the whole way creates the possibility of binding, splintering or tearing as the cutoff piece drops off. If you're using sawhorses, use a couple of 2x4s to cover the span.
When you have to rip a long piece of lumber, it's probably going to be better to do this on a table saw. But, if one's not handy, then you go to the trusty circular saw when the cut doesn't have to be totally accurate. The trick is how to keep the board in place while you are making the cut. If the piece isn't very wide, clamps are awkward to use; they get in the way. One way is to tack the lumber down to your sawhorses; let the nails protrude so they can be easily removed.
If you're ripping a more expensive piece of wood, use finish nails to the material in place, and pull them from the backside after making the cut.
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