Breaking down long lumber for projects
Bill Tindall, E.Tn.
Some people have dedicated a shop wall to a chop saw of some sort and lumber supports for rough cutting long boards into parts for projects. I don't have a place to set up this arrangement. Over time I have realized that for my work it would make no sense to do so.
I have two vises on the bench where I can lay lumber as log as it gets. The overhang is supported by a stool and cuts are made with hand saws.
For 4/4 lumber I often use a hand saw sharpened for hardwood. It took just 30 seconds to cut a length from this board to use for vertical posts in the corner cupboard.
For 8/4 lumber, and often 4/4, I use a buck saw. Once lengths are down to about 4' I cross cut on the table saw. Only a few broads are cut this way even for a large chest of drawers. The time difference between this way and a chop saw set up is insignificant for the number of things I build in a year.
Doing these rough cuts is an opportunity to practice hand sawing which pays off in other parts of a project. And it is a lot quieter and dust-free. I find the noise of a chop saw particularly bothersome.
