85Mm Track Saw – Unlock Precision Cuts For Flawless Woodworking

ByJim Boslice Track Saw

An 85mm track saw is a compact, highly precise cutting tool designed to make straight, splinter-free cuts on sheet goods, solid wood, and trim. It excels at delivering table saw accuracy in a portable package, guided by an aluminum track.

Mastering its use involves proper setup, secure clamping, and understanding plunge cutting techniques, which drastically improves cut quality for beginners and experienced woodworkers alike.

Ever struggled to get that perfectly straight, splinter-free cut on a large sheet of plywood or a long board? You know the feeling – wrestling a full sheet onto a table saw, or watching your circular saw wander off course, leaving you with a jagged edge and wasted material. It’s a common frustration for woodworkers, DIY home builders, and furniture hobbyists alike.

At The Jim BoSlice Workshop, we believe precision shouldn’t be a luxury. That’s why we’re diving deep into a game-changing tool that can revolutionize your cutting accuracy: the 85mm track saw. This powerful, compact saw, when paired with its guiding track, offers unparalleled precision and portability, making those once-daunting cuts a breeze.

In this comprehensive 85mm track saw guide, we’ll explore everything you need to know. We’ll uncover the immense benefits of integrating this tool into your workshop, walk you through essential setup and usage techniques, offer practical 85mm track saw tips for common projects, and even troubleshoot some common problems with 85mm track saw use. By the end, you’ll be ready to achieve professional-grade cuts with confidence and safety.

What Exactly is an 85mm Track Saw and Why Do You Need One?

Think of an 85mm track saw as the best parts of a circular saw and a table saw combined. It’s a handheld power saw, similar in appearance to a circular saw, but it’s specifically designed to run along an extruded aluminum track. This track guides the saw blade with incredible accuracy, ensuring perfectly straight cuts every single time.

The “85mm” refers to the typical blade diameter, making these saws exceptionally compact and maneuverable. This size is ideal for a wide range of tasks, from precise trim work to cutting down sheet goods.

The Precision Advantage for Every Project

One of the primary benefits of 85mm track saw ownership is the sheer accuracy it provides. Forget the days of measuring twice and cutting crooked once. The track acts as an unyielding fence, preventing blade drift and ensuring a perfectly straight line.

  • Splinter-Free Cuts: Most tracks saws feature a splinter guard strip on the track itself. This rubber strip presses down on the workpiece right where the blade cuts, virtually eliminating tear-out, especially on veneered plywood or laminates.
  • Unmatched Accuracy: The saw locks onto the track, ensuring cuts are perfectly straight and square, or at your desired bevel angle. This precision is crucial for furniture making, cabinetry, and any project where tight joints are paramount.
  • Reproducible Results: Once your track is set, you can make multiple identical cuts with ease, a huge time-saver for repetitive tasks.

Compact Power for Versatile Cuts

Despite its precision, the 85mm track saw remains a highly versatile and portable tool. It’s much easier to bring the saw to a large sheet of material than to wrestle the material onto a stationary machine.

  • Portability: You can take your track saw and its tracks to any job site or corner of your workshop. This makes it invaluable for DIY home builders working on site.
  • Space-Saving: For hobbyists with smaller workshops, a track saw can often replace the need for a large table saw, especially for breaking down sheet goods.
  • Diverse Applications: From cutting door bottoms and window sills to breaking down full sheets of plywood for cabinets, or even precise dadoes and grooves with the right blade, its uses are extensive.

Getting Started: Your 85mm Track Saw Setup Guide

Proper setup is key to unlocking the full potential of your track saw. Don’t rush this step. Taking a few extra minutes here will save you headaches later and ensure your cuts are consistently perfect.

Unboxing and Initial Inspection

When you first get your new 85mm track saw, take a moment to familiarize yourself with all its components. Read the manufacturer’s manual thoroughly. It contains critical safety information and specific instructions for your model.

  • Inspect for Damage: Check the saw, track, and any accessories for shipping damage.
  • Identify Controls: Locate the power switch, depth adjustment, bevel adjustment, and blade lock.
  • Understand the Plunge Mechanism: Most track saws are plunge saws, meaning the blade retracts into the housing until you actively push it down into the material.

Blade Selection and Installation

The right blade makes all the difference. For clean cuts on wood and sheet goods, you’ll typically want a high tooth count (e.g., 48T or 60T) carbide-tipped blade. Always ensure the blade is designed for your saw’s 85mm diameter and arbor size.

  1. Safety First: Always unplug the saw before changing blades.
  2. Blade Lock: Engage the blade lock button to hold the blade still.
  3. Arbor Nut: Use the provided wrench to loosen and remove the arbor nut. Remember, it’s usually reverse-threaded.
  4. Install New Blade: Ensure the teeth are facing the correct direction (usually indicated by an arrow on the blade and saw).
  5. Tighten Nut: Re-tighten the arbor nut securely, but don’t overtighten.

Setting Up Your Track

The track is your guiding star. Ensure it’s clean, stable, and correctly positioned for every cut.

  • Clean the Track: Wipe down the track to remove any dust or debris that could impede the saw’s smooth travel.
  • Position the Track: Place the track on your workpiece. Remember that the splinter guard strip indicates the exact cut line. Align this strip precisely with your pencil mark.
  • Secure the Track: This is a crucial step for preventing common problems with 85mm track saw slippage. Use track clamps (which often slide into a channel on the track) to firmly secure the track to your workpiece. Never rely on friction alone.
  • Adjust Saw to Track: Ensure your saw runs smoothly on the track. Some saws have adjustment knobs to fine-tune the fit, eliminating wobble.

Mastering the Cut: 85mm Track Saw Best Practices

Once your setup is dialed in, it’s time to learn how to 85mm track saw like a pro. These techniques will help you achieve consistent, high-quality results.

Safe and Secure Workpiece Clamping

Before you even think about cutting, ensure your workpiece is stable and safe. This is paramount for preventing kickback and ensuring accurate cuts.

  • Elevate Your Work: Place your material on a stable surface, such as sawhorses or a workbench, ensuring the cut line is clear of obstructions. Use sacrificial boards underneath to protect your work surface and allow the blade to cut through completely.
  • Clamp the Workpiece: Use reliable clamps to secure the workpiece to your support surface. This prevents movement during the cut, which can lead to inaccuracies or dangerous kickback.

The Plunge Cut Technique

Most 85mm track saws are designed for plunge cutting. This means the blade is retracted into the saw’s housing until you initiate the cut.

  1. Set Depth: Adjust the cutting depth so the blade passes through your material by about 1/8 to 1/4 inch (3-6mm). This ensures a clean cut without dulling the blade on your support surface.
  2. Position Saw: Place the saw on the track at the starting point of your cut, with the blade fully retracted.
  3. Engage Power: Turn on the saw, allowing the motor to reach full speed.
  4. Plunge Smoothly: With a controlled motion, depress the plunge lever and push the saw forward into the material along the track. Maintain steady, even pressure.
  5. Exit Cleanly: Continue through the cut until the blade clears the material, then release the plunge lever to retract the blade before turning off the saw.

Cross-Cutting and Ripping with Precision

The 85mm track saw excels at both cross-cutting (cutting across the grain) and ripping (cutting with the grain) large panels.

  • Cross-Cutting: For perfectly square cross-cuts, ensure your track is perpendicular to the edge of your material. A reliable square or speed square can help you align the track accurately.
  • Ripping: When ripping long panels, ensure your track is parallel to the edge. Measure from the edge of the material to the splinter guard strip at both ends of the cut to confirm parallel alignment.
  • Support Long Cuts: For very long rips, especially on thin materials, ensure adequate support along the entire length of the cut to prevent sagging and ensure a consistent cut.

Bevel Cuts Made Easy

Many 85mm track saws allow you to tilt the blade for bevel cuts, typically up to 45 or even 48 degrees.

  1. Adjust Bevel Angle: Loosen the bevel lock and set the desired angle using the saw’s angle scale.
  2. Test Cut: It’s always a good idea to make a test cut on a scrap piece of the same material to verify the angle before cutting your project piece.
  3. Maintain Control: Bevel cuts can sometimes feel different. Maintain a firm grip and steady pressure throughout the cut.

Common Problems with 85mm Track Saw and How to Fix Them

Even with the best tools, you might encounter a snag or two. Knowing how to troubleshoot common problems with 85mm track saw usage will save you time and frustration.

Dealing with Tear-Out

Tear-out, or splintering, is a common issue when cutting wood, especially plywood or veneered materials. Your track saw is designed to minimize this, but it can still occur.

  • Check Splinter Guard: Ensure the rubber splinter guard on your track is intact and making firm contact with the workpiece. If it’s worn, replace it.
  • Sharp Blade: A dull blade is the primary culprit for tear-out. Use a sharp, high-tooth-count blade (e.g., 48T-60T for fine cuts).
  • Proper Depth: Set the blade depth so it just barely clears the bottom of your material. Too shallow or too deep can sometimes contribute to tear-out.
  • Backer Board: For extremely delicate materials, use a sacrificial backer board underneath your cut line.

Track Slippage and Instability

The track moving during a cut is dangerous and will ruin your project. This is often due to insufficient clamping.

  • Use Track Clamps: Always use the dedicated track clamps designed for your system. These secure the track firmly to the workpiece.
  • Clean Track Bottom: Ensure the underside of your track is clean. Dust or sawdust can reduce friction and cause slippage.
  • Secure Workpiece: Make sure the workpiece itself is firmly clamped to your workbench or sawhorses.

Blade Binding and Motor Strain

If your saw bogs down, struggles, or the blade binds in the cut, it’s a sign something isn’t right.

  • Feed Rate: Don’t force the saw. Let the blade do the work. Maintain a consistent, moderate feed rate. Pushing too hard can lead to binding and motor strain.
  • Dull Blade: A dull blade requires more effort from the motor and is more prone to binding. Replace or sharpen your blade.
  • Incorrect Blade Type: Ensure you’re using the right blade for the material. A low-tooth-count blade for ripping will struggle on dense hardwoods or sheet goods.
  • Workpiece Support: If the material sags or closes in on the blade behind the cut, it can cause binding. Ensure adequate support on both sides of the cut.
  • Internal Track Friction: If the saw feels stiff on the track, check the fit adjustments. Too tight can cause friction.

Extending the Life of Your Tool: 85mm Track Saw Care Guide

Like any precision tool, your 85mm track saw requires regular care to maintain its performance and longevity. A well-maintained tool is not only more effective but also safer to use. Embracing a good 85mm track saw care guide also contributes to a more sustainable 85mm track saw ownership experience.

Blade Maintenance and Sharpening

Your blade is the heart of your cutting precision. Keep it clean and sharp.

  • Clean Blades: Resin and pitch buildup can dull a blade prematurely and increase friction. Use a specialized blade cleaner or oven cleaner to remove buildup after every few uses.
  • Sharpen or Replace: A professional sharpening service can extend the life of your blades significantly. If a blade is chipped or severely damaged, replace it. A sharp blade is safer and provides better cuts, reducing material waste and making your workshop more eco-friendly.
  • Proper Storage: Store blades in their original packaging or a dedicated blade case to protect the teeth from damage.

Track Cleaning and Storage

The track is just as important as the saw itself. Keep it pristine.

  • Wipe Down Regularly: After each use, wipe down your track with a dry cloth to remove sawdust and debris. For stubborn pitch, a little mineral spirits on a rag can work, followed by a dry wipe.
  • Inspect Splinter Guard: Periodically check the condition of the rubber splinter guard. If it’s damaged or heavily worn, it’s time for a replacement.
  • Store Flat and Protected: Store your tracks flat, ideally hanging on a wall or supported along their length, to prevent warping. Protect them from being scratched or dinged, as any damage to the track surface will affect cutting accuracy.

Motor and Housing Care

The saw itself needs attention too, especially its motor and moving parts.

  • Clean Vents: Regularly blow out the motor vents with compressed air to prevent sawdust buildup, which can cause overheating and shorten motor life.
  • Inspect Cord: Check the power cord for any cuts, fraying, or damage. Replace a damaged cord immediately for safety.
  • Lubricate Moving Parts: Consult your saw’s manual for specific lubrication points. Generally, a dry lubricant or light oil can be applied sparingly to plunge mechanisms or blade guard pivots to ensure smooth operation.
  • Brush Replacement: If your saw uses carbon brushes, be aware of when they might need replacement (often indicated by reduced power or excessive sparking). Refer to your manual for instructions.

Frequently Asked Questions About Your 85mm Track Saw

How accurate is an 85mm track saw compared to a table saw?

For breaking down sheet goods and making long, straight cuts, an 85mm track saw can be just as accurate, if not more so, than a table saw, especially for a beginner. The track eliminates human error in guiding the blade, ensuring a perfectly straight line.

Can I use my 85mm track saw without the track?

While technically possible, it’s not recommended. An 85mm track saw is designed to work with its guiding track for precision. Using it freehand will result in less accurate cuts and defeats the primary purpose and benefit of the tool. If you need a freehand saw, a standard circular saw is a better choice.

What kind of blade should I use for cutting plywood with my 85mm track saw?

For cutting plywood and other sheet goods, a high-tooth-count (48T-60T) carbide-tipped blade is ideal. These blades produce cleaner, splinter-free cuts on veneered materials, which is crucial for a professional finish.

How do I prevent my track from slipping on smooth materials?

Always use track clamps to secure the track to your workpiece. Additionally, ensure the underside of your track is clean. Some tracks also have non-slip strips on the bottom, which should be kept free of dust and debris for maximum grip.

Is an 85mm track saw a good investment for a beginner woodworker?

Absolutely! An 85mm track saw is an excellent investment for beginners. It simplifies the process of making accurate cuts, reduces frustration with tear-out, and offers a safer alternative for handling large sheet goods compared to a table saw. It builds confidence and allows you to achieve professional results from the start.

There you have it – a comprehensive look at the powerful and precise 85mm track saw. From understanding its fundamental benefits to mastering advanced cutting techniques and maintaining your tool for years to come, you now have the knowledge to elevate your woodworking projects.

Remember, the key to success with any power tool lies in patience, practice, and a commitment to safety. Take your time with setup, always wear appropriate personal protective equipment, and never rush a cut. With these 85mm track saw tips and a bit of practice, you’ll be making flawless, professional-grade cuts in no time.

Now, go forth and create something incredible. Stay safe, stay creative, and keep those cuts perfectly straight!

Jim Boslice
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