Cutting Sheet Goods
A full-sized table-saw and a helper, you’ll find no better combination for cutting full-sheet panels, with the possible exception of a panel saw. But if you are working alone, it is still possible to cut full panels down to size accurately and safely using a circular saw. The main difficulty beginners encounter when cutting panels with a circular saw is that they do not adequately support the waste so it falls away prematurely and ruins the cut (or causes an accident). Another common mistake is to support both ends so the area being cut binds on the saw blade as the cut is made. The solution is simply to support the entire panel along both edges with sacrificial scraps of 2 × 4. Set your saw blade to cut just slightly deeper than the thickness of the panel. The blade will score the 2 × 4s as it cuts, but they will continue to support the workpiece all the way through
the cut. Be sure to use a straightedge guide for your saw, and always cut with the good face down when using a circular saw.
Overlay Doors
Easy-to-build overlay doors, made with 1⁄2" finish-grade plywood panels framed with door-edge moldings, are designed to overhang the face frame by about 3⁄8" on each side. Semi-concealed overlay hinges, which require no mortising, are attached to the back of the door and to the edge of the face frame. This door style also can be adapted to make folding doors.
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