CUTSA WS

BY GLEN D. HUEY

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ince DeWalt and Makita entered the United States plunge-cut saw market with Fes-tool, the three have received immense interest and discussion. How are the saws different? Are the results of a crosscut or rip cut any cleaner than those made at a table saw? What features are common or unique on plunge-cut saws? I scrutinized a DeWalt DWS520, a Fes-tool TS55 and a Makita SP6000 to see which, if any. of the saws stand out.

If you're looking for vast differences in the cuts produced by the various plunge-cut saws, I'm afraid you're going to be disappointed. I used each saw to cut plywood and hardwood, both with and across the grain, and for slicing samples of melamine. There isasmall amount of tear-out (mostly across the grain as you might expect), but nothing significant. In fact, I compared those cuts with cuts made in the same materials at a table saw and again, the differences are minimal.

A Smooth Ride

A quick look at the guide rail or track designs is of interest. The Festool and Makiia guide rails look very similar in profile -so much so, that they fasten together and align. The DeWalt track hasa different profile. DeWalt's track issymmetrical and center-justified, which means you can operate the saw in both directions. With the others, you have to flip the rails tocut in a second direction. That could be an issue depending on the task.

Right on track. The commonality of these saws is a guide rail or track on which each slides - as well as the clean, straight cuts produced. Where differences show is in the unique features found when given a closer look.

But here's what is attention grabbing: All three plunge-cut saws ride and operate on a Festool guide rail. However, Festool's saw rides on a Makita track, but not on a DeWalt track. And a DeWalt saw doesn't work with a Makita track just as a Makita saw is not functional on a DeWalt track. Need a scorecard?

How Plunge-cut Saws Work The Festool and Makiia saws' plunge operation is like movingyour wrist in a hammering motion. The DeWalt saw moves a bit differently. It rocks forward to make a plunge cut with an action similar to moving something from one spot to another - lift, move, then set back down. Switching between the two different motions causes one to think, but individually, their use is intuitive.

What makes these saws operate as they do is the blade set with a "toe-in" design. This allows the saw to cut at the front of the blade with the back of the blade held away from the Ireshlycut edge. Minimal burn and little tear-out on the money side of the cut is the result. This is also the major difference between the finished cuts from these saws and those of a circular saw when used in combination with a straightedge guide.

There are other features common to these saws, such as t rackadj usters to dial in t he exact fit for a smooth slide, a lockable arbor for quick blade changes as well as blade depth-of-cut adjustments. And each saw is set up for dust extraction via an external vacuum. (See page 53 for more comparisons.)

A significant feature found on the DeWalt and Festool saws, but not on Makita'ssaw, is a riving knife. At first, you may question a riving knife's importance because the blade retracts into the saw if the tool is lifted from the track. But even with that action, there is still an opportunity for kickback and a riving knife defends aga.nst that action.

Not glue ready. The edges produced with plunge-cut saws are clean, but in the rake of the light, small saw marks can be seen.

All aboard. Plunge-cut saws work best when slid along a guide rail or track. What saw works with which track is interesting.

Properly set. A plunge-cut saw is set up with the blade slightly canted at the front. Here you can see the paper-thin gap needed to make a saw work its best.

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