What would you do?

[dewi1219]

A little background: I build a lot of cabinets and speakers which requires frequent ripping / crosscutting of large panels. Back at the beginning of summer I bought a used Craftsman RAS. It needed a new latch pin and table but was otherwise in excellent condition. And it was too good a deal to pass up. I had wanted one for years. For obvious reasons I always prefer keeping the stock stationary when cutting large panels if possible.

I recently bought an extra full set of rails on ebay. Got 'em fairly cheap, so now I am planning to build an obscenely large cabinet for my BT3. The plans include modular inserts for the extension wing which would allow me to place the SMT anywhere along the rails. This would make crosscutting large panels fairly simple though still not quite as simple as on the RAS. My shop is in an oversize 2-car garage that is used to park 2 cars. So all of my large tools are on mobile bases so I can store them against a wall when not in use. Therefore space is somewhat at a premium.

I have also always REALLY wanted a panel saw. Buying one is out of the question due to the cost, but I have several plans and could build one for a little more than what I could sell the RAS for.

So, my options are:
1) Sell the RAS and build a behemoth saw cabinet. With two full sets of rails and the infeed/outfeed supports I'm planning I would be able to rip or crosscut just about any size panel I would ever need. This would require the least amount of space in the shop.
2) Sell the RAS and build a panel saw. This would by far make crosscutting the easiest (maybe ripping too), and it would be built to fold up flat against a wall when not in use.
3) Do nothing. Keep the RAS and fix the table / latch pin. Maybe cut the extra rails in half and build a smaller cabinet for the BT3.

What would you do? I'm beginning to think I should sell the RAS, but that's a difficult choice as I have always loved them (for whatever reason). Al's post below about setting up the RAS as a dedicated dado machine intrigues me also.

[footprintsinconc]

i plan on doing what you say in option 2:

"build a panel saw. This would by far make crosscutting the easiest (maybe ripping too), and it would be built to fold up flat against a wall when not in use."

however, i plan on building onto my lumber storage rack.

[dbhost]

I have seen several very good designs for panel saws built onto lumber racks. Most of them make use of a circular saw as the cutter. I am reviewing several of those ideas. I may simply buy the plans for the one I like best. Ripping and crosscutting sheet goods can be a real PITA for sure!

[WoodTherapist]

Another option would be to sell the RAS and not build the larger BT3 cabinet or panel saw and instead purchase a Festool circular saw and guide rails. Then there is no need for a panel saw, larger BT3 or RAS. The Festool saw and guides are compact, easy to store and accurate. And it is safer, partly because the stock being cut is stationary. I use the Festool for all long rips and large sheet cuts and use an unmodified BT3 for cutting smaller pieces. I love how the combination of BT3 and Festool allow me to have a very compact shop.

[AAJIII]

I have a panel saw and IMHO there is no tool better suited for cutting large panels.

Now having said that I realise that not everyone has room for a panel saw and other options are ones that you mentioned as well as al of the other responses.

If you are going to be cutting large panels alot then if you can build/buy one then I do it.

Also you can build a couple of saw boards if you only need to cut panels once in a while.

Al

[dewi1219]

Another option would be to sell the RAS and not build the larger BT3 cabinet or panel saw and instead purchase a Festool circular saw and guide rails.

There are 3 problems with this idea:
1) Price
2) The Festool is very nice but when I need to make repetitive cuts I like a stationary saw with a stop for quick setup and accuracy.
3) Price
Plus, my very quick search did not find a Festool with a rail long enough to rip an 8ft sheet.

I have a panel saw and IMHO there is no tool better suited for cutting large panels.

Also you can build a couple of saw boards if you only need to cut panels once in a while.

Al, did you build or buy your panel saw? If you built it, which plan did you use? Right now I'm planning on using the ShopNotes frame with the Rockler sliding assembly. I like the simpler frame of the ShopNotes saw, but I like the 80/20 sliding assembly that Rockler uses. Plus, you can source the 80/20 parts on ebay for MUCH less than Rockler charges.

I have/use sawboards now, but as noted above I'm looking for something with quick setup and repeatability for multiple cuts.

[WoodTherapist]

There are 3 problems with this idea:
1) Price
2) The Festool is very nice but when I need to make repetitive cuts I like a stationary saw with a stop for quick setup and accuracy.
3) Price
Plus, my very quick search did not find a Festool with a rail long enough to rip an 8ft sheet.

Yeah, cost sure can be an issue with Festool, but with the sale of the RAS and the cost avoidance of the BT3 cabinet and panel saw, you could be in the neighborhood. Festool does make a guide rail for 8 foot rips. Festool makes several guide rails up to 16 feet long but they are pricey. A less expensive approach is to take the 55 inch guide rail that comes with the saw and use inexpensive joiners to connect it to another shorter rail in order to get to at least 96 inches. Quick setup with stops is not difficult – it just takes rethinking how you approach the work. And lack of accuracy is definitely not an issue. The biggest downside to Festool is that their products are addictive. The initial Festool cost as compared to the alternative costs may not be a big deal, as discussed. But then you must_have_more.

[AAJIII]

I bought mine from Tool Barn, by the way they beat Amazon on price hands down.

AL

[drumpriest]

I cut down sheets with a circ saw and straight edge just oversize, then make final cuts with TS. Very accurate and makes it safe to handle. I've only done finish cuts on 8' sheets a couple of times, it's a pain in the butt.

If you are planning to do full sheets on the bt, get some weight under that thing. It's not too hard to tip over a bt while pushing a 4x8 sheet through, I know by experience.

[dewi1219]

Ironically, an SSC H4 showed up on my local Craigslist this afternoon (I've never seen a panel saw on CL in my area before) for $650. Awesome deal if it's in decent shape, but I'm too cheap/broke to pay that much for something I can DIY.

[jon_ramp]

Have you considered the Eurekazone products as opposed to a panel saw?

[dewi1219]

I actually have looked at the Eurekazone stuff, and the price isn't too bad. But again, I think for repetitive cuts like I have to make sometimes a panel saw would serve me better. And I can still build a panel saw for about what the EZ stuff would cost for a decent setup. But I am open to the idea as a backup if all else fails.

[cwsmith]

Personally, I've found cutting sheet goods with a "factory edge" straight board and my cordless circular saw to be just the thing for me. I also have plans for a panel saw, but considering the cost (money and time), the straight board seems like the way to go for me.

A couple of years ago I acquired some maple flooring which I've glued up to make two sections, each about 14" wide. I lay these down on two folding saw horses and then position my sheet material on that, in a manner that allows my cut to fall between the two maple sections. Clamping my straight board in place I can make very accurate cuts without concern for either piece moving because of lack of support. Works for me, and the cost is negligible.

I get to keep my RAS and do whatever I want with the BT. (I really wouldn't want to loose either, and I don't have room for a permanent panel saw.)

CWS

[cabinetman]

I have seen several very good designs for panel saws built onto lumber racks. Most of them make use of a circular saw as the cutter. I am reviewing several of those ideas. I may simply buy the plans for the one I like best. Ripping and crosscutting sheet goods can be a real PITA for sure!

I like the idea of a vertical panel saw, on the order of the kind at HD and Lowes. They don't take up much of a footprint, and you don't have to maneuver sheets around on a table. This kit looks feasible.
.

[dewi1219]

Thanks for the link - that's a great looking kit. It could be easily duplicated with 80/20 if you want to save some money too. I really like the fold-up feature.