How Deep Can Track Saw Cut – Unlocking Precision & Power For Every

Most standard track saws, like the Festool TS 55 or Makita SP6000, can cut materials up to approximately 2-1/8 inches (54mm) thick at a 90-degree angle. This depth typically decreases when making bevel cuts.

The actual cutting depth depends on factors such as the saw’s blade diameter, motor power, and the specific material being cut.

Ever found yourself staring at a thick sheet of plywood or a hefty slab of hardwood, wondering if your trusty track saw is up to the task? You’re not alone. Many woodworkers, from seasoned pros to weekend DIY warriors, often ask: how deep can track saw cut?

Understanding your track saw’s cutting capacity isn’t just about avoiding a bogged-down motor; it’s about achieving clean, precise results and, most importantly, staying safe. Pushing your tool beyond its limits can lead to poor cuts, frustration, and even damage to your saw or workpiece.

At The Jim BoSlice Workshop, we believe in empowering you with the knowledge to master your tools. This comprehensive guide will dive deep into the world of track saw cutting depths. We’ll cover everything from what influences your saw’s capacity to practical tips for maximizing its performance, ensuring you make perfect cuts every single time. By the end, you’ll have a clear understanding of your track saw’s true potential and how to use it safely and effectively.

Understanding Your Track Saw’s Cutting Capacity: How Deep Can Track Saw Cut?

Let’s get straight to the heart of the matter: how deep can track saw cut, really? For most popular track saws on the market, like the Festool TS 55, Makita SP6000, or DeWalt DWS520CK, the typical maximum cutting depth at a 90-degree angle ranges from about 2 inches (50mm) to 2-1/8 inches (54mm). This is the depth you can expect when the saw is set for a straight, perpendicular cut through a flat surface.

However, this number isn’t static. It changes significantly when you introduce a bevel angle. For instance, a track saw capable of cutting 2-1/8 inches at 90 degrees might only manage around 1-5/8 inches (41mm) at a 45-degree bevel. Always check your specific saw’s manual for its exact specifications, as models can vary.

Understanding these basic specs is your first step in getting the most out of your tool. It helps you determine if your saw is suitable for the material thickness you’re working with before you even make the first plunge.

What the Numbers Mean: Standard Depths Explained

When you look at a track saw’s specifications, you’ll usually see two key depth measurements:

90-Degree Cut Depth: This is the maximum thickness of material the saw can cut when the blade is perfectly perpendicular to the workpiece. It’s the “straight down” cut.
45-Degree (or other) Bevel Cut Depth: This indicates the maximum depth when the saw is tilted to a specific angle, most commonly 45 degrees. Tilting the blade reduces the effective cutting depth because the blade enters the material at an angle.

These figures are usually based on the saw plunging through the material and clearing the track’s splinter guard. So, while a blade might physically extend a bit further, the usable depth is what’s important for a clean, track-guided cut.

Factors Influencing Track Saw Cutting Depth: Beyond the Spec Sheet

While the manufacturer’s specifications give you a baseline, several real-world factors can influence the actual, effective cutting depth you achieve. Understanding these will help you troubleshoot issues and get better results.

Blade Diameter and Kerf

The size of your saw blade is paramount. Most track saws use blades around 160mm (6-1/2 inches) or 165mm (6-1/2 inches) in diameter. A larger blade diameter generally allows for a deeper cut. However, you can’t just put any blade on your saw; it must match the saw’s arbor size and RPM rating.

The blade’s kerf (the width of the cut) also plays a role. Thinner kerf blades (e.g., 1.8mm) can sometimes feel like they cut deeper or with less effort because they remove less material. However, they can also be more prone to deflection if not handled correctly.

Material Density and Type

Cutting through soft pine is a completely different experience than slicing through dense hard maple or thick marine-grade plywood. The harder the material, the more resistance the blade encounters, and the more strain is put on the motor.

Softwoods (Pine, Cedar): Generally easier to cut, allowing the saw to maintain its stated depth with less effort.
Hardwoods (Oak, Maple, Walnut): Require more power and a slower feed rate. You might find that very deep cuts in dense hardwoods strain the motor, even if technically within the saw’s depth capacity.
Plywood & MDF: These engineered materials can sometimes be tougher than solid wood due to glues and varied grain direction.

For very dense materials, even if your saw theoretically has the depth, you might need to adjust your approach, which we’ll cover in the “Best Practices” section.

Motor Power and RPM

A track saw with a more powerful motor (higher wattage or amperage) will be better equipped to handle deeper cuts, especially in challenging materials. Higher RPM (revolutions per minute) helps maintain cutting efficiency, but it’s the motor’s torque that really pushes through resistance.

If your saw bogs down during a deep cut, it’s often a sign that the motor is struggling. This can lead to burning, inaccurate cuts, and premature wear on your tool.

Blade Sharpness and Type

This is one of the most overlooked factors. A dull blade dramatically reduces your saw’s effective cutting depth and efficiency. It forces the motor to work harder, creates more heat, and can lead to burning, tear-out, and a generally miserable cutting experience.

Always use a sharp blade appropriate for the material you’re cutting. Blades designed for cross-cutting have more teeth and a different tooth geometry than ripping blades, which are better for long grain cuts.

Track Usage and Splinter Guard

The track itself can slightly affect the effective depth. Your saw blade typically cuts through a replaceable splinter guard strip on the track. This strip consumes a tiny fraction of your blade’s overall reach. While minimal, it’s part of the design and accounted for in the published depth specifications.

Mastering Deep Cuts: How Deep Can Track Saw Cut Best Practices

Now that you know what influences your track saw’s depth, let’s talk about how deep can track saw cut best practices. These tips will help you achieve clean, accurate deep cuts every time.

Accurately Setting the Depth

Precise depth setting is fundamental. Your track saw will have a depth adjustment mechanism, often with a scale. Always double-check your setting against the actual material thickness.

Measure Your Material: Use calipers or a precise ruler to get the exact thickness.
Add a Hair: For through-cuts, add about 1/16 to 1/8 inch (1.5mm to 3mm) to your material thickness. This ensures the blade fully clears the material and slightly scores your sacrificial support board, preventing tear-out on the underside.
Test Cut: For critical projects, make a test cut on scrap material of the same thickness. This verifies your depth setting and allows you to fine-tune it.

Making Multiple Passes for Thick Materials

This is a “pro” tip for handling materials at the upper limit of your saw’s capacity, or even slightly beyond. Instead of trying to cut through a very thick piece in one go, make multiple passes.

First Pass (Shallow): Set the depth to cut about half the material’s thickness. This reduces strain on the motor and helps establish a clean kerf.
Second Pass (Deeper): After the first pass, reset the depth to fully cut through the material. The initial shallow cut helps guide the blade for the second pass, resulting in a cleaner finish.

This technique is especially useful for dense hardwoods or when you want to minimize strain on your saw.

Blade Selection for the Job

As mentioned, the right blade makes all the difference. For deep cuts, especially in hardwoods, you’ll want a sharp blade with the correct tooth count and geometry.

General Purpose: A 48-tooth ATB (Alternate Top Bevel) blade is a good all-rounder for plywood and general cutting.
Ripping (Deep, Long Grain): A lower tooth count (e.g., 24-30 teeth) with a larger gullet can be more effective for deep cuts along the grain, as it clears chips more efficiently.
Cross-Cutting (Deep, Across Grain): A higher tooth count (e.g., 60-80 teeth) provides a smoother finish but requires a slower feed rate, especially in deep material.

Always ensure your blade is clean and sharp. A dull blade is a dangerous blade and will never give you optimal depth.

Secure Clamping and Material Support

For any cut, but especially deep ones, your material must be absolutely stable. Use high-quality clamps to secure your workpiece to your workbench or sawhorses. The track itself should also be clamped down firmly.

Ensure your material is fully supported along the entire length of the cut, both on the main piece and the offcut. Unsupported sections can sag, bind the blade, or cause dangerous kickback. Use sacrificial foam boards or rigid insulation underneath your workpiece to protect your workbench and provide tear-out free support.

Consistent Feed Rate

Maintain a steady, controlled feed rate. Don’t rush, but don’t go too slow either. Too fast can bog down the motor and cause rough cuts or burning. Too slow can also cause excessive heat buildup and burning, especially with a dull blade.

Let the saw do the work. Listen to the motor; it will tell you if you’re feeding too fast or too slow.

Common Problems with Track Saw Cutting Depth and How to Solve Them

Even with the best preparation, you might encounter issues. Here are some common problems with how deep can track saw cut and practical solutions.

Burning or Bogging Down

This is a classic sign of your saw struggling. The blade might leave burn marks on the wood, or the motor might sound like it’s losing power.

Problem: Dull blade, incorrect feed rate, cutting too deep in one pass for the material, or insufficient motor power for the task.
Solution:
- Replace or sharpen your blade.
- Reduce your feed rate.
- Make multiple shallow passes instead of one deep one.
- Ensure your saw’s motor is adequately powerful for the material.

Inaccurate Depth of Cut

You set the saw to cut 1-1/2 inches, but it’s only cutting 1-3/8 inches, or worse, not fully through.

Problem: Incorrect depth scale calibration, blade not fully plunging, or material bowing.
Solution:
- Calibrate your saw’s depth scale if possible (consult your manual).
- Ensure the depth stop is fully engaged and not obstructed.
- Double-check that the track is fully seated on the material and not lifting.
- Check for material bowing and clamp securely.
- Perform a test cut on scrap to verify actual depth.

Excessive Tear-Out

Even with a splinter guard, deep cuts can sometimes cause significant tear-out on the top or bottom surface.

Problem: Dull blade, wrong blade type, worn splinter guard, or insufficient support under the material.
Solution:
- Use a sharp blade with a high tooth count (e.g., 48T or 60T) for fine cuts.
- Replace the splinter guard on your track if it’s damaged or worn.
- Always use a sacrificial board (e.g., rigid foam insulation) under your workpiece to provide zero-clearance support at the blade exit point.
- Ensure the track is pressed firmly against the material.

Blade Deflection

The blade bends or wobbles during a deep cut, leading to an uneven or non-square cut.

Problem: Pushing too hard, dull blade, thin blade, or improperly clamped material.
Solution:
- Reduce feed pressure; let the saw do the work.
- Use a sharper, possibly slightly thicker kerf blade.
- Ensure your material is securely clamped and fully supported.
- Check that the blade is properly installed and the arbor nut is tight.

Maximizing Your Track Saw’s Potential: Advanced Tips for Deeper Cuts

Beyond the basics, there are ways to push your track saw’s capabilities and get even more utility out of its cutting depth. These how deep can track saw cut tips are for those ready to refine their craft.

Utilizing Plunge Depth Stops

Most track saws have adjustable plunge depth stops. These are incredibly useful for repetitive cuts or when you need to make non-through cuts like dados or grooves.

Set the main depth to your desired maximum. Then, use the micro-adjustment or fine-tune knob to achieve the exact depth for your specific application. This ensures consistency across multiple pieces, which is essential for furniture making or cabinetry.

Bevel Cuts and Their Impact on Depth

Remember that beveling significantly reduces your effective cutting depth. When planning a project with angled cuts, always account for this reduction. For example, if you need to cut a 1-1/2 inch thick board at a 45-degree bevel, your saw might need to be capable of a 2-1/4 inch 90-degree cut to achieve that. Consult your saw’s manual for its specific bevel depth chart.

Always make sure your bevel angle is securely locked before starting a cut.

Making Dados and Grooves with Precision

Your track saw isn’t just for through-cuts. It excels at creating precise dados (grooves across the grain) and grooves (grooves along the grain) for joinery. Here’s how to ensure accurate depth:

Set Initial Depth: Set your saw’s depth to slightly less than your desired final depth.
First Pass: Make your first pass along the track.
Adjust and Repeat: Incrementally increase the depth and make subsequent passes until you reach your final desired depth. This technique, similar to multiple passes for through-cuts, reduces strain and ensures a clean-bottomed dado.
Clean Out: For wider dados, make multiple passes side-by-side or use a chisel to clean out the waste between passes.

Safety First: Essential Precautions for Deep Track Saw Cuts

Safety is paramount in any woodworking endeavor, especially when making deep cuts that put more strain on your tools and potentially increase kickback risk. These are non-negotiable practices.

Personal Protective Equipment (PPE): Always wear safety glasses, hearing protection, and a dust mask. Deep cuts generate more dust and noise.
Secure the Workpiece: As discussed, ensure your material and track are clamped securely. Movement during a deep cut can cause kickback or lead to inaccurate and dangerous situations.
Clear the Work Area: Keep your workspace free of clutter. Ensure you have a clear path for the saw and that the power cord won’t snag.
Inspect Your Blade: Before every deep cut, check your blade for damage, dullness, or missing teeth. A compromised blade is a major safety hazard.
Never Force the Cut: Let the saw’s motor do the work. Forcing a deep cut can lead to kickback, motor strain, and blade deflection.
Unplug Before Adjustments: Always unplug your saw before changing blades, adjusting depth, or performing any maintenance.
Know Your Saw: Read your saw’s manual cover to cover. Understand all its features, limitations, and safety warnings.

Caring for Your Track Saw: A Guide for Consistent Performance

To ensure your track saw continues to deliver its maximum cutting depth and precision for years to come, proper maintenance is key. This is your how deep can track saw cut care guide.

Blade Maintenance: Cleaning and Sharpening

A clean, sharp blade is the single most important factor for optimal cutting depth and quality. Pitch and resin buildup on saw blades significantly reduce their efficiency, making them feel dull even if the carbide teeth are still sharp.

Clean Regularly: Use a specialized blade cleaner (like CMT Formula 2050 or Simple Green) and a brass brush to remove pitch and resin. Always wear gloves and eye protection.
Sharpen or Replace: Have your blades professionally sharpened when they become dull. For many hobbyists, replacing blades is often more practical due to the cost of sharpening services vs. new blades. Keep a spare sharp blade on hand.

Track Maintenance: Keeping it Straight and True

Your track is just as important as your saw. A damaged or dirty track will compromise your cuts.

Keep it Clean: Wipe down your track regularly to remove dust, sawdust, and debris. This ensures the saw glides smoothly.
Check for Damage: Inspect the track for dents, bends, or damage to the rubber splinter guard and anti-slip strips. Replace damaged components as needed.
Proper Storage: Store your track in a way that prevents it from bending or being damaged, ideally hanging it vertically or laying it flat on a stable surface.

Motor and Brush Care

Most modern track saws have brushless motors that require less maintenance. If your saw has a brushed motor, periodically check and replace the carbon brushes according to the manufacturer’s recommendations. This ensures consistent power and extends motor life.

General Cleaning and Storage

After each use, give your saw a quick wipe-down to remove sawdust. Store it in its Systainer or original case to protect it from dust and accidental damage. Proper storage protects delicate components and keeps your investment safe.

Frequently Asked Questions About How Deep Can Track Saw Cut

Can I cut a 2×4 with a track saw?

Yes, most standard track saws can easily cut through a 2×4 (which is actually 1.5 inches x 3.5 inches). Their typical maximum depth of 2 to 2-1/8 inches at 90 degrees is more than sufficient for this task.

Does using the track reduce the cutting depth?

Technically, yes, but minimally. The blade has to cut through the track’s replaceable splinter guard strip, which accounts for a tiny fraction of the overall blade extension. The manufacturer’s stated depth specifications typically account for this, so the advertised depth is the usable depth with the track.

What if my track saw isn’t cutting deep enough?

First, check your depth setting and ensure it’s locked. Then, inspect your blade for dullness or pitch buildup. Ensure the material isn’t bowing and that you’re not trying to cut through something significantly harder than anticipated. Making multiple passes can also help.

Can I cut metal with a track saw?

While some specialized track saws or specific models might offer accessories for cutting very thin, non-ferrous metals (like aluminum with a special blade), most standard woodworking track saws are not designed for cutting metal. Using them for metal can be dangerous, damage the tool, and void your warranty. Always refer to your manufacturer’s guidelines.

Is it safe to cut at the maximum depth?

Yes, it is safe to cut at the maximum depth as long as you follow all safety precautions, use a sharp, appropriate blade, and maintain a controlled feed rate. The saw is designed to operate at its maximum capacity, but doing so requires extra care and attention to detail.

Mastering the art of deep cuts with your track saw is a rewarding journey. By understanding your tool’s capabilities, applying best practices, and prioritizing safety, you’ll achieve unparalleled precision and efficiency in your woodworking projects.

Remember, every cut is an opportunity to learn and improve. Don’t be afraid to experiment on scrap pieces, listen to your saw, and always put safety first. With these insights from The Jim BoSlice Workshop, you’re well on your way to becoming a true track saw master.

Stay sharp, stay safe, and keep building!

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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.