Dewalt Track Saw Dws520 – Master Precision Cuts For Flawless

ByJim Boslice Track Saw

The DeWalt Track Saw DWS520 is an essential tool for achieving incredibly accurate, splinter-free cuts on sheet goods and solid lumber.

It significantly improves cut quality and safety compared to a standard circular saw, especially for breaking down large panels.

Ever wrestled a full sheet of plywood onto a table saw, praying for a straight cut, only to end up with a wobbly edge and a pile of splintered frustration? We’ve all been there. Trying to achieve professional-grade accuracy with a standard circular saw on large materials can feel like an uphill battle.

But what if you could make those cuts with laser-like precision, right where the material lies, without the heavy lifting or the inevitable tear-out? Imagine perfectly straight edges, every single time, ready for assembly.

That dream is a reality with the right tool. This comprehensive guide will show you how the DeWalt Track Saw DWS520 can transform your woodworking, making those daunting tasks simple and precise. We’ll cover everything from setup and usage to advanced tips, troubleshooting, and essential care, helping you unlock its full potential for your projects.

Understanding Your DeWalt Track Saw DWS520: More Than Just a Circular Saw

When you first look at the DeWalt Track Saw DWS520, it might resemble a circular saw. However, this tool is a different beast entirely, designed for precision and efficiency that a regular circular saw simply can’t match. It’s a game-changer for anyone working with sheet goods, solid wood, or even laminate flooring.

The core difference lies in its guided cutting system. Instead of freehanding a cut, the DWS520 locks onto an aluminum track, ensuring a perfectly straight line every time. This integration with the track is what elevates it from a good tool to an indispensable one.

Key Benefits of the DeWalt Track Saw DWS520

Investing in a track saw, especially the robust DWS520, brings a host of advantages to your workshop. These benefits directly translate into better project outcomes and a more enjoyable woodworking experience.

  • Unmatched Precision: The track guides the saw blade with incredible accuracy. This virtually eliminates crooked cuts, making it ideal for furniture components, cabinet parts, and precise joinery.
  • Splinter-Free Cuts: The DWS520 features a scoring function or a replaceable splinter guard strip on the track. This prevents tear-out, giving you clean, finished edges straight off the saw, reducing sanding time significantly.
  • Superior Dust Collection: With its enclosed blade housing and effective dust port, the DWS520 offers excellent dust extraction. This creates a cleaner, healthier work environment, which is a major plus for any workshop.
  • Portability and Versatility: Unlike a large table saw, you can take your track saw to the material, not the other way around. This is invaluable for breaking down large sheets of plywood or MDF right where they’re delivered, saving your back and space.
  • Enhanced Safety: The plunge-cut mechanism keeps the blade retracted until you’re ready to cut, reducing accidental contact. The saw stays firmly on the track, minimizing kickback risks.

Getting Started: Your DeWalt Track Saw DWS520 Guide for First-Time Users

Unboxing your new DeWalt Track Saw DWS520 is exciting! To ensure you get off to a safe and successful start, follow these steps. Proper setup is crucial for achieving the precision this tool is known for.

Initial Setup and Safety First

Before you even plug in your saw, take a moment to familiarize yourself with its components and safety features. Always wear appropriate personal protective equipment (PPE), including safety glasses, hearing protection, and a dust mask.

  1. Unpack and Inspect: Carefully remove all components from the box. Check the saw, tracks, and accessories for any shipping damage.
  2. Install the Blade: The DWS520 typically comes with a blade, but you might want to upgrade to a finer tooth count for specific materials.
    • Unplug the saw.
    • Press the spindle lock button.
    • Use the included wrench to loosen the arbor bolt (it’s reverse thread, so turn clockwise to loosen).
    • Remove the outer flange and old blade.
    • Install the new blade, ensuring the teeth point in the direction of rotation (usually marked on the blade and saw).
    • Replace the outer flange and tighten the arbor bolt securely (counter-clockwise).
  3. Attach the Dust Bag/Hose: Connect the included dust bag or your shop vacuum hose to the dust port. This is essential for clean cuts and a healthy workspace.

Setting Up Your Track and Saw

The track is the heart of the system. Learning how to DeWalt track saw DWS520 effectively begins with proper track setup.

  1. Position Your Material: Place the material you intend to cut on a stable surface, ideally with sacrificial foam insulation or sawhorses that allow the blade to cut through without damaging your workbench.
  2. Lay the Track: Position the track on your material where you want the cut line. Remember, the edge of the track serves as your guide. The splinter guard strip on the track indicates exactly where the blade will cut.
  3. Secure the Track: Use track clamps to firmly secure the track to your material. This prevents any movement during the cut, which is vital for precision and safety. Don’t skip this step!
  4. Adjust Depth of Cut: On the DWS520, adjust the depth setting so the blade cuts approximately 1/8″ to 1/4″ deeper than your material thickness. This ensures a clean through-cut.
  5. Set Bevel Angle (If Needed): If you need a beveled cut, adjust the saw’s base to the desired angle. The DWS520 allows for negative bevels, which is great for undercutting.

Mastering the Cut: Advanced DeWalt Track Saw DWS520 Tips and Best Practices

Once you’re comfortable with the basics, these best practices will help you get the most out of your DeWalt Track Saw DWS520, ensuring consistent, high-quality results every time.

Achieving the Perfect Cut

Precision isn’t just about the tool; it’s also about your technique. These tips will help you refine your approach.

  • First Pass – Score Cut: For materials prone to splintering (like melamine or veneered plywood), make a very shallow scoring cut (about 1/16″ deep) on your first pass. This sets the splinter guard and creates a clean top edge. Then, follow up with a full-depth cut.
  • Consistent Pressure and Feed Rate: Maintain a steady, even pressure and feed rate throughout the cut. Rushing or hesitating can lead to uneven cuts, burning, or increased tear-out. Let the saw do the work.
  • Support Your Material: Ensure both sides of your cut are well-supported to prevent the material from sagging or pinching the blade. This is especially important for long rips on thin sheet goods.
  • Use the Plunge Mechanism: The DWS520 is a plunge saw. Start with the blade retracted, position the saw at the start of your cut, engage the motor, and then smoothly plunge the blade into the material. Retract the blade before lifting the saw.
  • Consider Blade Choice: While the stock blade is good, specific tasks might benefit from different blades. A higher tooth count (e.g., 48T or 60T) provides cleaner cuts on plywood and laminates, while a lower tooth count (e.g., 24T) is better for faster rips in solid wood.

Eco-Friendly and Sustainable Practices

As woodworkers, we often work with natural resources. Incorporating sustainable practices with your DeWalt Track Saw DWS520 isn’t just good for the planet; it’s good for your wallet too.

  • Optimize Material Yield: Plan your cuts carefully using layout software or by dry-fitting templates. Minimizing waste saves material and money. The DWS520’s precision helps you utilize every inch of your stock.
  • Proper Blade Maintenance: A sharp blade cuts more efficiently, consumes less power, and reduces wear on your saw. Instead of discarding dull blades, look into professional sharpening services. This extends blade life and reduces waste.
  • Responsible Dust Management: Effective dust collection isn’t just about safety; it’s also about collecting wood waste for proper disposal or even repurposing. Fine sawdust can be composted or used as animal bedding.
  • Extend Tool Lifespan: A well-maintained tool lasts longer, reducing the need for premature replacement. This is a core aspect of a sustainable DeWalt Track Saw DWS520 approach.

Troubleshooting Common Problems with Your DeWalt Track Saw DWS520

Even the best tools can encounter issues. Knowing how to diagnose and fix common problems with your DeWalt Track Saw DWS520 will save you time and frustration, keeping your projects on track.

Addressing Cut Quality Issues

If your cuts aren’t as clean or straight as they should be, consider these potential causes:

  • Splintering/Tear-out:
    • Cause: Dull blade, incorrect feed rate, worn splinter guard, or not performing a scoring cut.
    • Solution: Replace or sharpen the blade. Slow down your feed rate. Replace the splinter guard strip on the track. Always make a shallow scoring pass first on delicate materials.
  • Crooked or Tapered Cuts:
    • Cause: Track not securely clamped, track bowing, or blade not square to the base.
    • Solution: Ensure track clamps are tight. Use a straightedge to check the track for bowing, especially on long cuts. Check and adjust the saw’s 90-degree stop using a reliable square.
  • Burning on the Wood:
    • Cause: Dull blade, too slow a feed rate, or cutting too deep for the material/blade type.
    • Solution: Install a sharp blade. Increase your feed rate slightly. Ensure the blade is appropriate for the material you’re cutting.

Saw Operation Challenges

Sometimes the issue isn’t the cut, but how the saw itself is behaving.

  • Saw Sticking or Binding on Track:
    • Cause: Track guides on the saw need adjustment, or the track itself is dirty.
    • Solution: The DWS520 has adjustment screws on its base to fine-tune the fit to the track. Adjust them so the saw glides smoothly but without excessive play. Clean the track rails with a dry cloth.
  • Excessive Dust:
    • Cause: Dust port blocked, dust bag full, or connection to shop vac is loose.
    • Solution: Clear any blockages. Empty the dust bag or canister. Ensure all dust collection connections are snug.
  • Motor Overheating or Loss of Power:
    • Cause: Overworking the saw, dull blade, or an electrical issue.
    • Solution: Allow the saw to cool. Replace a dull blade. Reduce the depth of cut for very dense materials. If issues persist, consult a qualified technician.

Maintaining Your Investment: A DeWalt Track Saw DWS520 Care Guide for Longevity

Your DeWalt Track Saw DWS520 is a precision tool, and like any valuable investment, it thrives with proper care. Following a regular maintenance routine ensures its longevity, consistent performance, and continued safety.

Regular Cleaning and Inspection

A clean saw is a happy saw. Dust and debris are the enemies of precision tools.

  • After Every Use:
    • Disconnect from power.
    • Use a brush or compressed air to remove sawdust from the motor vents, blade area, and plunge mechanism.
    • Wipe down the saw’s body and the track with a dry or slightly damp cloth. Pay special attention to the track’s guide rails.
    • Check the power cord for any cuts or damage.
  • Periodically:
    • Inspect the blade for sharpness, missing teeth, or cracks. Replace if necessary.
    • Check all screws and fasteners for tightness.
    • Examine the splinter guard strip on the track. If it’s worn or damaged, replace it to maintain tear-out free cuts.
    • Clean the track guide rails thoroughly, ensuring no sticky residue builds up.

Storage and Protection

How you store your DWS520 and its tracks can significantly impact their lifespan.

  • Store in a Clean, Dry Place: Protect your saw and tracks from moisture, extreme temperatures, and direct sunlight.
  • Use a Case or Bag: If your saw came with a case, use it! This protects the saw from impacts and keeps dust out.
  • Proper Track Storage: Store tracks flat or in a dedicated track bag/rack to prevent warping. Never lean them against a wall where they might bend over time. A warped track will lead to inaccurate cuts.

By following this DeWalt Track Saw DWS520 care guide, you’re not just preserving your tool; you’re ensuring it continues to deliver the precise, high-quality results you expect for years to come.

Frequently Asked Questions About the DeWalt DWS520 Track Saw

Is the DeWalt Track Saw DWS520 worth it for a hobbyist?

Absolutely! While an investment, the DWS520’s precision, ease of use, and ability to handle large sheet goods safely make it incredibly valuable for hobbyists who want professional results without a large table saw taking up space. It significantly elevates the quality of your furniture and DIY projects.

Can I use other brands’ tracks with the DeWalt DWS520?

The DeWalt DWS520 is generally designed to work best with DeWalt tracks. While some users report compatibility with certain other brands (like Festool or Makita tracks) with slight adjustments or specific adapters, it’s always recommended to use DeWalt’s own tracks for optimal performance, safety, and maintaining warranty.

What is the best blade for the DeWalt Track Saw DWS520?

The “best” blade depends on the material you’re cutting. For general-purpose work on plywood and MDF, a 48-tooth ATB (Alternate Top Bevel) blade is a great all-rounder. For extremely fine, splinter-free cuts on veneered plywood or laminates, a 60-tooth or 80-tooth blade will yield superior results. For rough ripping of solid wood, a 24-tooth or 32-tooth blade might be more efficient.

How do I prevent kickback with my DeWalt Track Saw DWS520?

Kickback is rare with a track saw if used correctly, but it can happen. To prevent it: always ensure the track is securely clamped to the workpiece. Maintain a firm grip on the saw. Use a consistent feed rate. Never force the saw. Ensure your workpiece is fully supported and that the offcut isn’t pinching the blade. The DWS520 also has an anti-kickback mechanism that engages with the track for added safety.

How do I replace the splinter guard on the DeWalt track?

The splinter guard is typically adhesive-backed and fits into a channel along the edge of the track. To replace it: carefully peel off the old, worn strip. Clean the channel thoroughly to remove any adhesive residue. Peel the backing off the new strip and carefully align it with the channel, pressing it firmly into place along the entire length of the track. Once installed, make a shallow cut with your DWS520 along the length of the track to trim the new guard perfectly to your blade’s kerf.

The DeWalt Track Saw DWS520 is more than just a power tool; it’s a precision system that empowers you to create with confidence. By understanding its capabilities, following best practices for setup and cutting, and committing to regular care, you’ll unlock a new level of accuracy and efficiency in your woodworking.

From breaking down large sheets for cabinetry to crafting intricate furniture components, this guide has provided you with the knowledge to master your DWS520. Embrace the precision, enjoy the cleaner cuts, and elevate your craft.

Stay safe, keep learning, and happy building!

Jim Boslice
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