Dewalt Track Saw Blade Size – Your Guide To Precision & Performance

You’ve invested in a DeWalt track saw, and you know the kind of precision it brings to your workshop. It’s a game-changer for breaking down sheet goods and making perfectly straight, splinter-free cuts. But here’s the thing: even the best tool is only as good as its accessories. When it comes to getting those flawless results, understanding the right dewalt track saw blade size is absolutely critical.

Many woodworkers, especially those new to track saws, often wonder if one blade fits all. The short answer is no, not if you want to achieve professional-level finishes and extend the life of your blade and saw. Choosing the correct blade size and type can feel a bit overwhelming with all the options out there.

Don’t worry, you’re in the right place. This comprehensive guide will demystify everything about dewalt track saw blade size. We’ll walk you through the standard specifications, explain how tooth count impacts your cuts, and share expert tips for selecting, using, and maintaining your blades. By the end, you’ll be confident in picking the perfect blade for any project, ensuring cleaner cuts, better performance, and a safer woodworking experience.

Understanding the Standard Dewalt Track Saw Blade Size

Let’s start with the fundamentals. When you’re looking for a replacement blade or upgrading your current one, there are two primary measurements you need to know for your DeWalt track saw: the blade’s diameter and its arbor size.

Most DeWalt track saws, like the popular DWS520CK or the FlexVolt models, are designed around a very specific blade size. Getting this wrong can lead to improper fit, poor cut quality, and even dangerous situations.

Blade Diameter: 165mm (6-1/2 inches)

The standard dewalt track saw blade size for diameter is 165mm, which is approximately 6-1/2 inches. This is a crucial measurement. Blades that are too large won’t fit within the saw’s housing or align with the track properly. Blades that are too small won’t offer sufficient depth of cut or might cause the saw to bind.

• Why it matters: The saw’s guard, dust collection shroud, and overall design are built around this specific diameter. Using a different size compromises safety and performance.
• What to look for: Always check the packaging or product description for “165mm” or “6-1/2 inches.”

Arbor Size: 20mm

Equally important is the arbor size. This refers to the diameter of the hole in the center of the blade that fits onto the saw’s spindle. For DeWalt track saws, the standard arbor size is 20mm.

• Why it matters: A blade with an arbor hole that’s too small simply won’t fit. An arbor hole that’s too large will cause the blade to wobble, leading to inaccurate cuts, excessive vibration, and a high risk of kickback or blade damage.
• What to look for: Confirm the blade specifies a “20mm arbor.” Some blades come with reducer rings, but it’s best to find a blade with the native 20mm arbor for optimal fit and stability.

Kerf Width: Thin vs. Standard

While not strictly part of the dewalt track saw blade size, the kerf width (the thickness of the cut the blade makes) is an important consideration. Most track saw blades feature a relatively thin kerf, typically around 2.2mm or 0.087 inches.

• Benefits of thin kerf: It removes less material, reducing strain on your saw and potentially extending battery life for cordless models. It also means less sawdust and a finer cut.
• Compatibility: Your saw and track are designed for a specific kerf to ensure the splinter guard works effectively. Stick to blades with a kerf similar to your original DeWalt blade.

Decoding Blade Tooth Count: How to Choose for Your Project

Once you have the correct dewalt track saw blade size (165mm diameter, 20mm arbor), the next big decision is the tooth count. This is where you really tailor your blade to the material you’re cutting and the finish you want to achieve. The tooth count dictates both the speed of your cut and its smoothness.

Generally, fewer teeth mean faster, coarser cuts, ideal for ripping solid wood. More teeth mean slower, finer cuts, perfect for delicate materials and crosscuts.

Low Tooth Count (24T): For Fast Ripping

Blades with around 24 teeth are considered low tooth count. These blades have larger gullets (the spaces between the teeth), which are excellent for clearing chips quickly.

• Best use: Primarily for ripping solid lumber along the grain, fast cuts in softer woods, and rough framing.
• Benefits: Very efficient for removing material, reduces heat buildup during long rips.
• Drawbacks: Leaves a rougher cut that often requires significant sanding. Not suitable for plywood or delicate materials.
• Pro Tip: Even with a track saw, a 24T blade might still cause some tear-out on the bottom side of plywood. Consider a sacrificial board underneath.

Medium Tooth Count (48T): The Versatile Workhorse

A 48-tooth blade is often the general-purpose blade that comes standard with many track saws. It strikes a great balance between speed and finish quality.

• Best use: Excellent for general-purpose crosscutting, breaking down sheet goods like plywood and MDF, and many woodworking tasks.
• Benefits: Provides a relatively smooth cut in a variety of materials without sacrificing too much speed.
• Recommendation: If you only want one blade for your DeWalt track saw, a good quality 48T blade is your best bet for overall versatility. This is a great starting point for any dewalt track saw blade size guide.

High Tooth Count (60T+): For Flawless Finish Cuts

When you need the absolute cleanest cut, especially on delicate or expensive materials, a blade with 60 or more teeth is the way to go.

• Best use: Perfect for crosscutting hardwoods, cutting veneered plywood, melamine, laminates, and plastics where tear-out is unacceptable.
• Benefits: Produces a remarkably smooth, splinter-free cut that often requires little to no sanding.
• Drawbacks: Cuts slower and generates more heat, requiring a slower feed rate. More prone to pitch buildup due to smaller gullets.
• Pro Tip: For ultra-fine materials like melamine, look for blades with a Triple Chip Grind (TCG) tooth configuration in addition to a high tooth count.

Beyond Size: Blade Types and Materials for Optimal Cuts

The dewalt track saw blade size and tooth count are essential, but the actual construction of the blade also plays a huge role in its performance and longevity. Understanding blade materials and tooth configurations will further refine your blade selection.

Carbide-Tipped Blades: The Industry Standard

Almost all quality circular saw blades today, especially for track saws, are carbide-tipped. This means small pieces of tungsten carbide are brazed onto the steel blade body to form the cutting teeth.

• Benefits: Carbide is much harder and more durable than steel, allowing blades to stay sharp longer and withstand the demands of cutting various materials.
• Quality matters: Not all carbide is created equal. Higher-quality carbide tips will hold their edge longer and be more resistant to chipping.

Tooth Configurations: ATB, TCG, and Combination

The shape and grind of the carbide teeth also significantly impact the cut quality.

• ATB (Alternate Top Bevel): This is the most common grind for general-purpose blades. The teeth are alternately beveled left and right, creating a knife-like shearing action. Excellent for crosscutting and general work in wood and plywood.
• TCG (Triple Chip Grind): These blades have alternating trapezoidal and flat teeth. The trapezoidal tooth cuts a groove, and the flat tooth cleans out the corners. Ideal for cutting abrasive materials like laminates, melamine, MDF, and non-ferrous metals.
• Combination: Some blades feature groups of ATB teeth followed by a raker tooth, designed for both ripping and crosscutting. While versatile, dedicated blades usually outperform them for specific tasks.

Coatings and Anti-Friction Features

Many premium blades, including those from DeWalt and other manufacturers, feature special coatings or design elements.

• Anti-friction coatings: These reduce heat buildup, minimize pitch and resin accumulation, and allow the blade to glide through material more easily. This extends blade life and improves cut quality.
• Expansion slots: Laser-cut slots in the blade body help dissipate heat and prevent blade warping, especially during long cuts.

Common Problems with Dewalt Track Saw Blade Size & Performance

Even with the right dewalt track saw blade size, you might encounter issues if the blade isn’t properly maintained or used. Understanding these common problems can help you troubleshoot and achieve consistently clean cuts.

Tear-Out and Splintering

This is probably the most frustrating issue for any woodworker. Tear-out happens when the blade pulls fibers out of the wood rather than cutting them cleanly.

• Causes:
  • Dull blade: A sharp blade shears fibers; a dull one rips them.
  • Wrong tooth count: Too few teeth for delicate material.
  • Too fast feed rate: Giving the blade insufficient time to cut cleanly.
  • Improper setup: Splinter guard not correctly positioned or worn out.
• Solution: Ensure your blade is sharp, use a high tooth count blade (60T+ for fine work), reduce your feed rate, and verify your splinter guard is intact and properly adjusted.

Burning or Scorching the Wood

If you see dark, burnt marks along your cut line, your blade is overheating.

• Causes:
  • Dull blade: The most common culprit. A dull blade rubs more than it cuts, generating friction and heat.
  • Too slow feed rate: If you move too slowly, the blade sits in one spot, building up heat.
  • Pitch buildup: Accumulated resin on the blade can cause friction.
  • Wrong blade for material: A low tooth count blade in dense hardwood can overheat.
• Solution: Sharpen or replace your blade, clean it regularly, increase your feed rate slightly (but don’t force it), and ensure you’re using an appropriate blade for the material.

Blade Wobble or Excessive Vibration

A wobbly blade is not only dangerous but also leads to wide, inaccurate, and rough cuts.

• Causes:
  • Incorrect arbor size: If the arbor hole is too large, the blade won’t seat properly.
  • Improperly tightened arbor nut: Always ensure the nut is securely fastened.
  • Damaged blade: A bent blade or a missing/chipped tooth can cause imbalance.
  • Saw issues: Less common, but worn bearings or a bent arbor on the saw itself can be the cause.
• Solution: Double-check the dewalt track saw blade size for proper arbor fit, ensure the arbor nut is tight, inspect the blade for damage, and if problems persist, have your saw inspected.

Dewalt Track Saw Blade Size Best Practices for Longevity and Safety

To get the most out of your blades and keep your workshop safe, adopting some best practices is essential. These tips go beyond just picking the right dewalt track saw blade size; they cover the entire lifecycle of your blade.

Regular Cleaning: The Secret to Blade Life

Saw blades accumulate pitch, resin, and sawdust, especially when cutting softwoods or treated lumber. This buildup causes friction, heat, and dulls the blade prematurely.

• How to clean:
  1. Always unplug your saw first.
  2. Remove the blade from the saw.
  3. Soak the blade in a specialized blade cleaner (like CMT 2050 or Simple Green) for 10-15 minutes.
  4. Use a stiff nylon brush (not wire, which can damage carbide) to scrub off any remaining residue.
  5. Rinse thoroughly with water and immediately dry the blade to prevent rust.
• Frequency: Clean your blade after every few hours of use, or whenever you notice performance dropping.

Proper Storage: Protecting Those Precious Teeth

A dull or damaged blade is a dangerous blade. Store your blades carefully to protect the carbide teeth.

• Best methods:
  • Store blades in their original packaging.
  • Use dedicated blade cases or sleeves.
  • Hang blades on a pegboard using a large washer to prevent teeth from touching the wall.
• Avoid: Storing blades loosely in a drawer where they can bump into other tools or blades.

Sharpening vs. Replacing: When to Do What

High-quality carbide blades can be sharpened multiple times, significantly extending their life. This is a key part of any dewalt track saw blade size care guide.

• Sharpening:
  • When: When cuts become rough, you notice burning, or tear-out increases, even after cleaning.
  • Who: Send your blades to a professional saw blade sharpening service. They have the specialized equipment to restore the precise carbide geometry.
  • Cost: Sharpening is usually much cheaper than buying a new blade.
• Replacing:
  • When: If teeth are severely chipped, cracked, missing, or if the blade body itself is bent or warped. These issues are often beyond repair.
  • Consider: The cost-effectiveness. If a blade has been sharpened many times and is losing its edge quickly, it might be time for a new one.

Safe Blade Changes: A Non-Negotiable Step

Changing your blade might seem simple, but it’s a moment when accidents can easily happen. Always prioritize safety.

• Steps:
  1. UNPLUG THE SAW from the power source (or remove the battery). This is the absolute first step.
  2. Consult your DeWalt track saw manual for specific instructions on blade removal.
  3. Use the provided arbor wrench and blade lock button to loosen the arbor nut.
  4. Carefully remove the old blade, keeping your fingers away from the teeth.
  5. Clean the arbor flanges and spindle area.
  6. Install the new blade, ensuring the teeth are oriented correctly (they should point in the direction of saw rotation, usually indicated by an arrow on the blade).
  7. Tighten the arbor nut securely, but do not overtighten.
  8. Check that the blade spins freely and the guards operate correctly before plugging the saw back in.

Sustainable & Eco-Friendly Dewalt Track Saw Blade Size Choices

As woodworkers, we often think about the materials we use for our projects, but what about the tools themselves? Making sustainable and eco-friendly choices extends to your dewalt track saw blade size and maintenance.

Prioritize Quality for Longevity

Investing in higher-quality carbide-tipped blades, even if they cost a bit more upfront, pays off in the long run. These blades are designed to last longer and withstand more sharpenings.

• Reduced waste: A blade that lasts longer means fewer blades ending up in landfills.
• Better performance: Quality blades maintain their edge better, leading to more efficient cuts and less material waste from botched cuts.

Embrace Sharpening Over Replacement

This is perhaps the most significant eco-friendly practice. Sharpening your blades instead of constantly buying new ones drastically reduces your environmental footprint.

• Resource conservation: Less demand for new blades means less raw material extraction and manufacturing energy.
• Cost savings: Sharpening is usually a fraction of the cost of a new blade.

Proper Blade Cleaning and Maintenance

As discussed, regular cleaning prevents premature dulling and extends blade life. This simple act contributes to sustainability by keeping your blades in top working condition for longer.

• Energy efficiency: A clean, sharp blade requires less power from your saw to make a cut, especially for cordless models, extending battery life and reducing energy consumption.

Dewalt Track Saw Blade Size Tips: Pro Advice for Flawless Results

Beyond the basics, here are some advanced dewalt track saw blade size tips and general best practices from experienced woodworkers to help you get the most out of your track saw and achieve truly flawless results every time.

Always Perform a Test Cut

Before making a critical cut on expensive material, always do a test cut on a scrap piece of the same material. This allows you to check for tear-out, burning, or any other issues and adjust your blade choice, depth, or feed rate accordingly.

Adjust Blade Depth Correctly

For optimal dust collection and reduced tear-out, set your blade depth so that the teeth just clear the bottom of your material by about 1/8 to 1/4 inch. Too deep, and you increase the risk of kickback and wear on the blade. Too shallow, and the cut might not be clean.

Control Your Feed Rate

The speed at which you push the saw through the material is crucial. Too fast, and you risk tear-out, burning, and motor strain. Too slow, and you risk burning and excessive heat buildup.

• General rule: Let the blade do the work. Listen to the saw’s motor; it should maintain a consistent RPM. Adjust your feed rate to keep the motor sounding strong and steady.
• Material variation: Dense hardwoods require a slower feed rate than softwoods or plywood.

Utilize Dust Extraction

Your DeWalt track saw has excellent dust collection capabilities. Always connect it to a shop vac or dust extractor. This not only keeps your shop cleaner but also improves visibility of your cut line and helps keep the blade cooler by removing sawdust that can cause friction.

Consider Dedicated Blades for Specialty Materials

While a 48T blade is versatile, if you frequently work with specific materials like laminates, plastics, or non-ferrous metals, investing in a dedicated blade (e.g., a TCG 60T+ blade) will provide superior results and extend the life of your general-purpose blades.

Remember, the right dewalt track saw blade size guide isn’t just about matching numbers; it’s about matching the blade’s characteristics to the demands of your project. Pay attention to the details, and your track saw will reward you with exceptional precision.

Frequently Asked Questions About Dewalt Track Saw Blade Size

What is the standard Dewalt track saw blade size?

The standard blade size for DeWalt track saws is 165mm (6-1/2 inches) in diameter with a 20mm arbor hole. Always confirm these specifications when purchasing a new blade.

Can I use a standard circular saw blade on my DeWalt track saw?

No, you cannot. While some standard circular saws might use 6-1/2 inch blades, they typically have a different arbor size (often 5/8 inch) and a wider kerf. Using an incompatible blade will result in improper fit, poor performance, and is extremely dangerous. Always use blades specifically designed for track saws with the correct 165mm x 20mm dimensions.

How often should I sharpen my track saw blade?

The frequency depends on your usage and the materials you cut. A good rule of thumb is to sharpen your blade when you notice a decrease in cut quality (e.g., increased tear-out, burning), even after a thorough cleaning. For hobbyists, this might be once or twice a year; for heavy users, it could be every few weeks.

What’s the best blade for cutting melamine with a DeWalt track saw?

For cutting melamine, which is prone to chipping, you’ll want a high tooth count blade, typically 60 teeth or more, with a Triple Chip Grind (TCG) tooth configuration. The TCG design is specifically engineered to shear through brittle laminates cleanly, minimizing tear-out on both sides of the material.

Does blade kerf matter for track saws?

Yes, blade kerf (the thickness of the cut) matters. Most track saw blades have a relatively thin kerf, which works optimally with the saw’s splinter guard and dust extraction system. Using a blade with a significantly different kerf can compromise the effectiveness of the splinter guard and affect cut accuracy.

Choosing the right dewalt track saw blade size and type is a cornerstone of precise woodworking. It’s not just about getting the cut done; it’s about getting it done right, safely, and efficiently. By understanding the standard dimensions, selecting the appropriate tooth count, and committing to proper blade care, you elevate your craftsmanship and get the most out of your powerful DeWalt track saw.

Remember, a sharp, clean, and correctly chosen blade is your best friend in the workshop. It prevents frustration, saves material, and most importantly, ensures your safety. So take these insights to heart, confidently select your next blade, and keep creating those beautiful, precise projects. Stay safe and keep those cuts clean!

• Author
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Jim Boslice

Jim Boslice is a power tool enthusiast who tests, reviews, and shares practical guides to help DIYers and professionals choose the right tools for every project.

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