Resawing With A Track Saw – Unlock Thin Stock & Veneer Without

Ever found yourself with a beautiful piece of lumber, wishing you could stretch it further, perhaps turn one thick board into two thinner ones, or even create your own custom veneer? You’re not alone. Many woodworkers face the challenge of needing thinner stock for a project but lack the specialized machinery like a large bandsaw. It can feel like a bottleneck in your creative process.

But what if I told you that your trusty track saw, a tool you probably already rely on for precise sheet goods and panel cuts, can also unlock a world of possibilities for milling thinner lumber? It’s true! With the right approach and a bit of know-how, mastering

resawing with a track saw

can transform your workshop capabilities.

In this comprehensive guide, we’ll dive deep into the art and science of resawing using this versatile tool. We’ll cover everything from essential gear and meticulous setup to step-by-step techniques and crucial safety practices. You’ll learn how to overcome common challenges and discover expert tips to achieve clean, consistent results every time. Get ready to expand your woodworking horizons and make the most out of every board.

What is Resawing and Why Use a Track Saw for It?

Resawing is the process of cutting a thicker piece of wood along its grain into two or more thinner pieces. Think of it as slicing a loaf of bread lengthwise. This technique is invaluable for creating custom veneers, making thinner panels for cabinet doors, or simply maximizing your lumber yield from an expensive board.

Traditionally, resawing is done on a bandsaw, which has a large throat capacity and a thin blade ideal for deep cuts. However, a quality track saw offers compelling advantages, especially for the home workshop.

The Benefits of Resawing with a Track Saw

Using a track saw for resawing might seem unconventional, but it brings several key advantages to the table:

• Exceptional Precision: Track saws are renowned for their laser-straight cuts. The guided track ensures your cut line is perfectly accurate, minimizing waste and post-cut cleanup.
• Portability and Versatility: Unlike a stationary bandsaw, a track saw is portable. You can take it to the material, making it ideal for larger or unwieldy boards that are difficult to maneuver on a bandsaw.
• Safety for Beginners: Compared to a table saw (which can be very dangerous for resawing without specialized jigs) or even a bandsaw, a track saw offers a controlled cutting experience. The blade is largely enclosed, and the track keeps the saw stable.
• Cost-Effectiveness: If you already own a track saw, learning to resaw with it saves you the significant expense and space required for a dedicated bandsaw.
• Reduced Tear-out: With the right blade and technique, a track saw can produce very clean cuts, especially on the top surface, reducing the amount of sanding or planing needed afterward.

While a track saw has limitations in terms of maximum cutting depth, for many common resawing tasks, it’s an incredibly effective and often superior solution for achieving precise, thin stock.

Essential Gear for Successful Resawing with a Track Saw

To achieve clean, accurate results when resawing with a track saw, having the right tools and accessories is paramount. Think of this as your essential checklist before you even make your first mark.

Your Track Saw and Blade Choice

The star of the show is, of course, your track saw. Brands like Festool, Makita, DeWalt, and Triton all offer excellent options. Ensure your saw is in good working order, with a clean base and a smoothly operating plunge mechanism.

The most critical component for resawing is the blade.

• Rip Blades: A dedicated rip blade with fewer teeth (e.g., 24-30 teeth) and a larger gullet is ideal. It clears sawdust more efficiently and reduces heat buildup, which is crucial for deep cuts.
• Combination Blades: If a rip blade isn’t available, a general-purpose combination blade with around 40-48 teeth can work, but it will cut slower and generate more heat.
• High Tooth Count Blades: Avoid fine-tooth crosscut blades (60+ teeth) for resawing. They will clog, overheat, and burn the wood.

Always use a sharp, clean blade. A dull blade will cause excessive burning, strain your saw, and produce a poor cut quality.

Clamping and Workpiece Support

Stability is non-negotiable when resawing. You’ll need:

• Plenty of Clamps: Track clamps are essential for securing the track to your workpiece. Additionally, C-clamps, F-style clamps, or quick-grip clamps are vital for securing the workpiece itself to your workbench or sawhorses. The board must not move during the cut.
• Sturdy Workbench or Sawhorses: Your cutting surface needs to be solid and flat. Any movement or wobble will compromise your cut accuracy and safety.
• Sacrificial Support: Place a sacrificial board (MDF, plywood, or scrap wood) under your workpiece to prevent tear-out on the underside and protect your workbench.

Measurement and Marking Tools

Accuracy starts with precise layout. Gather these:

• Measuring Tape or Ruler: For measuring your desired thickness.
• Pencil or Marking Knife: A sharp pencil or a marking knife for clear, precise lines. A marking knife is often preferred for greater accuracy.
• Square or Combination Square: To ensure your layout lines are perfectly square to the edge of the board.
• Featherboards (Optional but Recommended): While not strictly necessary, featherboards can help keep the workpiece tight against your fence (if using a fence setup) or track, reducing vibration and increasing stability.

Safety Gear (PPE)

Your safety is paramount. Always wear:

• Safety Glasses: Protect your eyes from flying dust and debris.
• Hearing Protection: Track saws can be loud, especially during extended cuts.
• Dust Mask or Respirator: Resawing generates a lot of fine sawdust. A dust collection system connected to your track saw is highly recommended.

Having all these items ready before you start will ensure a smoother, safer, and more successful resawing experience.

Step-by-Step Guide: How to Resaw with a Track Saw Safely

Now that you have your gear ready, let’s walk through the process of

how to resaw with a track saw

effectively and, most importantly, safely. This technique relies on making multiple, precise passes.

Step 1: Prepare Your Workpiece

Start with a board that has at least one flat face and one straight edge. This is crucial for accurate referencing against your track.

• Square Up: If your board isn’t already dimensioned, square up one face and one edge. These will be your reference surfaces.
• Mark Your Cut Line: Measure the desired thickness for your thinner boards. For example, if you want two 3/8″ thick pieces from a 1″ board, you’ll aim for a cut roughly in the middle, accounting for the blade kerf. Use a marking gauge or a ruler and pencil to draw a clear line around all four sides of the board. This line will serve as your visual guide.

Step 2: Set Up Your Workspace

A stable setup is key to preventing mistakes and ensuring safety.

• Secure the Workpiece: Place your board on a sturdy workbench or sawhorses with a sacrificial board underneath. Clamp it down firmly using at least two, preferably more, clamps. The board absolutely must not move during the cut.
• Attach Dust Collection: Connect your track saw to a shop vac or dust extractor. Resawing produces a lot of dust, and good dust collection improves visibility and air quality.

Step 3: Position and Secure the Track

This is where the precision of the track saw shines.

• Align the Track: Position your track directly over your marked line on the first face of the board. The splinter guard on your track should align perfectly with the cut line.
• Clamp the Track: Secure the track to the workpiece using track clamps. Ensure it’s tight and won’t shift. Double-check your alignment.

Step 4: Set the Blade Depth for Multiple Passes

Unlike a bandsaw, a track saw can’t cut through a thick board in a single pass. You’ll make several passes, gradually deepening the cut.

• First Pass Depth: Set your blade depth to cut approximately half to two-thirds of the board’s thickness from the first side. For example, on a 1″ thick board, set the depth to about 1/2″ to 5/8″. Ensure the blade clears the bottom of the track slightly.

Step 5: Make Your First Cut

With everything secure, it’s time to cut.

• Proper Stance: Stand comfortably, keeping your body out of the direct line of the saw’s travel.
• Smooth, Consistent Feed Rate: Engage the saw and make a smooth, steady pass along the track. Don’t rush it, but don’t stop mid-cut either. Let the saw do the work. Listen to the motor; if it’s bogging down, you might be feeding too fast.
• Complete the Pass: Push the saw completely through the board’s length.

Step 6: Flip the Board and Repeat

This is the core of

resawing with a track saw tips

for thickness.

• Flip and Re-clamp: Carefully unclamp and flip the board over, end-for-end. Re-clamp it securely to your workbench.
• Align Track for Second Side: Position the track over the marked line on the second face of the board. Crucially, the track should be aligned perfectly opposite the first cut you made. This ensures your cuts meet in the middle. Clamp the track down firmly.
• Make Second Cut: Set the blade depth to match your first pass, and make another smooth, consistent cut.

Step 7: Continue with Subsequent Passes (if needed)

For very thick boards, you might need more than two passes.

• Deeper Passes: After the first two passes (one from each side), you’ll have a kerf on both faces. Now, you can make deeper passes. Increase the blade depth slightly (e.g., another 1/4″ to 3/8″) and repeat Step 5 and Step 6.
• Meeting in the Middle: Continue this process, gradually deepening the cut from alternating sides, until your cuts meet in the middle. The goal is for the two kerfs to meet cleanly, leaving you with two thinner pieces.

Step 8: Separate and Finish

Once the cuts meet, the two pieces should separate.

• Gentle Separation: If they don’t separate easily, a slight tap with a mallet or a gentle wedge might be needed. Avoid forcing them.
• Clean Up: You’ll likely have a slight ridge or unevenness where the two cuts met. This is normal. Use a hand plane, jointer, or sander to flatten and smooth the resawn faces to your desired final thickness.

Remember, practice makes perfect. Start with some scrap wood to get a feel for the process before tackling your prized lumber.

Maximizing Precision and Preventing Common Problems with Resawing with a Track Saw

While the track saw is fantastic for precision,

common problems with resawing with a track saw

can arise without proper attention to detail. Here’s how to ensure your cuts are as accurate as possible and avoid frustrating issues.

Achieving Perfect Alignment

The key to straight resawn boards is perfect track alignment on both sides.

• Marking Knife for Precision: Use a marking knife instead of a pencil for your layout lines. This creates a fine, crisp line that the splinter guard can register against with greater accuracy.
• Measure from Reference Edge: When flipping the board, don’t just eyeball the track placement. Re-measure the distance from your established reference edge to the track’s splinter guard on both sides to ensure consistency.
• Use a Straight Edge for Verification: After clamping the track, lay a long, known straight edge across your workpiece and track to visually confirm that the track is perfectly parallel to your marked cut line and not angled.

Blade Selection and Care

Your blade is your primary cutting tool; treat it well.

• Sharpness is Non-Negotiable: A dull blade will burn the wood, cause the saw to bog down, and lead to inaccurate cuts. Have your blades professionally sharpened regularly.
• Clean Your Blade: Resawing builds up pitch and sawdust on the blade. Clean it with a dedicated blade cleaner to maintain its cutting efficiency.
• Use the Right Blade: As mentioned, a rip or combination blade is best. Avoid crosscut blades.

Feed Rate and Depth Control

These two factors significantly impact cut quality.

• Consistent, Moderate Feed Rate: Don’t try to force the saw. Let the blade do the work. A consistent, moderate feed rate prevents burning, reduces strain on the motor, and results in a smoother cut. If you hear the motor laboring, slow down.
• Gradual Depth Increase: Resist the urge to take too deep a cut in each pass. Smaller, more frequent passes are safer and produce better results, especially with harder woods.

Supporting Long Boards

Longer boards are more prone to bowing or flexing, affecting accuracy.

• Outfeed Support: Always use adequate outfeed support. Roller stands or additional sawhorses aligned with your workbench will prevent the board from dropping or twisting as you push the saw through.
• Central Support: For very long boards, ensure support along the entire length of the cut to prevent sagging in the middle.

Addressing Common Issues

Knowing how to troubleshoot keeps your project on track.

• Uneven Cuts: This is almost always due to inconsistent track alignment when flipping the board. Re-check your measurements and marking.
• Blade Binding or Burning: This indicates a dull blade, too fast a feed rate, or insufficient dust extraction. Slow down, check your blade, and ensure your dust collector is working efficiently.
• Tear-out: While track saws generally minimize tear-out, it can still occur. Ensure your splinter guard is intact and making good contact. A fresh, sharp blade also helps. For stubborn woods, a scoring pass (a very shallow cut) before the main pass can help prevent tear-out.

By paying close attention to these details, you’ll significantly improve your results and make

resawing with a track saw

a reliable technique in your woodworking repertoire.

Advanced Tips for Sustainable Resawing with a Track Saw

Wood is a precious resource, and as woodworkers, we have a responsibility to use it wisely.

Sustainable resawing with a track saw

isn’t just about saving money; it’s about respecting the material and minimizing waste.

Maximizing Material Yield

Every cut counts, especially with expensive or rare lumber.

• Plan Your Cuts: Before you even touch the saw, plan how many thin pieces you need and what their final thickness will be. Account for the blade kerf and any subsequent milling (planing, sanding) to clean up the resawn faces.
• Go for Thinner Stock: If your project allows, aim for the thinnest practical stock. This lets you get more pieces from a single board, stretching your material further.
• Consider Bookmatching: Resawing is perfect for creating bookmatched panels. Cut a board in half, open it like a book, and glue the edges together for a stunning, symmetrical grain pattern. This makes two thinner pieces look like a single, wider piece.

Minimizing Waste and Embracing Offcuts

Even the smallest pieces can have a purpose.

• Efficient Layout: Lay out your cuts carefully to minimize the size and number of offcuts. Sometimes, shifting your resaw line by an eighth of an inch can yield a usable strip instead of a tiny scrap.
• Save Your Scraps: Don’t automatically toss thin offcuts. They can be invaluable for test pieces, small decorative inlays, shims, or even kindling.
• Eco-Friendly Resawing with a Track Saw: By optimizing your cuts and using a precise tool like a track saw, you inherently reduce waste compared to less accurate methods. This practice aligns perfectly with eco-conscious woodworking.

Understanding Wood Grain and Stability

Resawing changes the stresses within a board.

• Read the Grain: Before resawing, examine the board’s grain. Straight-grained lumber will be more stable after resawing than highly figured or wild-grained pieces, which may cup or warp.
• Allow for Acclimation: After resawing, especially thicker stock into thin pieces, allow the newly exposed surfaces to acclimate to your shop’s humidity for a few days before final milling. This helps stabilize the wood and reduces the chances of warping.
• Rough Cut First: For very valuable or tricky pieces, consider resawing slightly oversized, letting the wood stabilize, and then doing your final dimensioning.

By adopting these advanced tips, you’re not just improving your craftsmanship; you’re also becoming a more mindful and sustainable woodworker, ensuring that every piece of lumber is honored and utilized to its fullest potential.

Track Saw Care Guide for Consistent Resawing Performance

Your track saw is an investment, and proper maintenance ensures it performs optimally for tasks like resawing. A well-maintained saw is a safe and accurate saw. This

resawing with a track saw care guide

will help you keep your tool in top shape.

Blade Maintenance

The blade is the heart of your saw’s cutting ability.

• Keep it Clean: Pitch and resin buildup on saw blades significantly reduce cutting efficiency and increase heat. Use a specialized blade cleaner (like a citrus-based solvent) and a brass brush to remove buildup after every few hours of use, or after any particularly resinous wood.
• Keep it Sharp: A dull blade causes burning, tear-out, and puts strain on your saw’s motor. Don’t wait until your blade is struggling; send it out for professional sharpening as soon as you notice a decline in performance. Having a spare blade allows you to keep working while one is being sharpened.
• Proper Storage: Store blades in their original packaging or a dedicated blade case to protect the delicate carbide teeth from damage when not in use.

Track Maintenance

The track is crucial for guiding your saw straight.

• Keep it Clean: Wipe down your track regularly to remove sawdust, dirt, and any sticky residue. A clean track ensures your saw glides smoothly and accurately.
• Check Splinter Guard: The splinter guard is essential for tear-out free cuts. Inspect it for damage. If it’s worn or chipped, replace it.
• Inspect for Damage: Check the aluminum track for any dents, bends, or nicks. Even minor damage can affect the straightness of your cuts.
• Store Properly: Store your track flat, preferably hanging on a wall or on a dedicated shelf, to prevent it from bending or warping.

Saw Body and Motor Care

The main unit also needs attention.

• Clean Exterior: Wipe down the saw body after each use to remove sawdust. Pay attention to the areas around the motor vents to ensure proper airflow.
• Check Carbon Brushes (if applicable): If your saw uses carbon brushes, periodically check them for wear and replace them before they wear out completely, as this can damage the motor. Consult your saw’s manual for specific instructions.
• Cord Inspection: Regularly inspect the power cord for any cuts, fraying, or damage. A damaged cord is a serious safety hazard and should be repaired or replaced immediately by a qualified professional.

General Care Tips

A few overarching practices will extend the life of your tool.

• Read the Manual: Familiarize yourself with your specific track saw’s manual. It contains valuable information on maintenance schedules, troubleshooting, and safety.
• Protect from Moisture: Store your track saw and track in a dry environment to prevent rust and corrosion.
• Regular Inspections: Before each use, quickly inspect your saw and track for any loose parts, damage, or excessive wear. Address any issues before you start cutting.

By following these simple care guidelines, your track saw will continue to be a reliable and precise tool for all your woodworking needs, including high-performance resawing.

Safety First: Essential Practices for Resawing with a Track Saw

Woodworking is incredibly rewarding, but it demands respect for your tools and adherence to strict safety protocols. When engaging in tasks like resawing, which involves deep cuts into solid wood,

resawing with a track saw best practices

always begin with safety.

Personal Protective Equipment (PPE)

Never skip your PPE. It’s your first line of defense.

• Safety Glasses: Always wear impact-resistant safety glasses or a face shield to protect your eyes from flying debris and sawdust.
• Hearing Protection: Track saws, especially when cutting through thick lumber, can generate significant noise. Earplugs or earmuffs are essential to protect your hearing.
• Dust Mask/Respirator: Resawing creates a substantial amount of fine wood dust. A quality dust mask or respirator is crucial to protect your respiratory system. Ensure your track saw’s dust collection is connected and functioning optimally.

Workpiece and Track Security

Movement is your enemy when cutting.

• Secure the Workpiece: Clamp your board firmly to a stable workbench or sawhorses. It should not move, shift, or vibrate during the cut. Use multiple clamps if necessary.
• Secure the Track: Always clamp your track securely to the workpiece. A shifting track will lead to inaccurate cuts and could cause the saw to bind or kick back.
• Stable Support: Ensure your workbench or sawhorses are stable and don’t wobble. Any instability can transfer to your cut.

Safe Operation Practices

Mindful operation reduces risk.

• Clear Workspace: Keep your work area free of clutter, tripping hazards, and distractions. Ensure adequate lighting.
• Proper Stance: Maintain a balanced stance, keeping your body out of the direct line of the blade’s travel. Don’t lean directly over the saw.
• Check Blade Depth: Double-check your blade depth setting before each pass to ensure it’s appropriate for the cut and won’t cut into your workbench.
• Consistent Feed Rate: Feed the saw at a consistent, moderate pace. Forcing the saw or stopping mid-cut can lead to binding, kickback, or burning. Let the saw do the work.
• Never Reach Over the Blade: Keep your hands clear of the blade’s path at all times. Wait for the blade to stop completely before removing the saw from the track or handling the workpiece.
• Unplug When Changing Blades or Adjusting: Always unplug your track saw from the power source before changing blades, making significant adjustments, or performing any maintenance.

By integrating these safety practices into every resawing operation, you’ll protect yourself and ensure a successful, injury-free woodworking experience. Remember, a safe woodworker is a happy woodworker.

Frequently Asked Questions About Resawing with a Track Saw

You’ve got questions, and we’ve got answers. Here are some common queries about using your track saw for resawing.

Can you resaw thick wood with a track saw?

Yes, you can resaw relatively thick wood with a track saw, but there are limits. The maximum thickness you can resaw is determined by the maximum cutting depth of your specific track saw. For most track saws, this is typically around 2-1/8 to 2-3/4 inches. You achieve this by making multiple passes from each side of the board, gradually deepening the cut until the two kerfs meet in the middle.

What kind of blade is best for resawing?

For resawing, a dedicated rip blade with a lower tooth count (e.g., 24-30 teeth) and larger gullets is generally best. This type of blade efficiently clears sawdust, reduces heat buildup, and minimizes burning. If a rip blade isn’t available, a general-purpose combination blade (40-48 teeth) can work, but avoid fine-tooth crosscut blades as they will quickly clog and overheat.

Is resawing dangerous?

Any operation involving a power saw carries inherent risks, but resawing with a track saw can be quite safe when proper precautions are followed. The track saw’s guided nature and blade enclosure reduce many risks associated with freehand cutting or table saw resawing. The main safety concerns are ensuring the workpiece and track are securely clamped, using a sharp blade, maintaining a consistent feed rate, and always wearing appropriate PPE (safety glasses, hearing protection, dust mask).

How do I prevent blade marks when resawing?

Blade marks (or burning) are typically caused by a dull blade, too slow a feed rate, or excessive friction. To prevent them: ensure your blade is sharp and clean, use a consistent and appropriate feed rate (don’t force it, but don’t dwell), and ensure good dust extraction. Making multiple, shallower passes can also help reduce heat buildup and burning.

Can I resaw veneer with a track saw?

Yes, resawing with a track saw is an excellent method for creating custom veneers, especially for smaller projects or specific wood species. The precision of the track saw allows for very thin, consistent slices. However, be aware that very thin veneers (under 1/16″) can be fragile and prone to breaking during the cut or handling. It’s often best to resaw slightly thicker than your final desired veneer and then sand or plane it down.

Embrace the Versatility of Your Track Saw!

You’ve now got the knowledge and the steps to confidently tackle

resawing with a track saw

. This technique, once reserved for specialized machinery, is now firmly within your grasp, offering a precise, controlled, and accessible way to expand your woodworking capabilities. Imagine the possibilities: crafting custom veneers, milling thinner stock from precious lumber, or simply maximizing your material yield on a budget.

Remember, like any new skill, practice is key. Start with some scrap wood, get a feel for the setup, the feed rate, and the process of making those alternating passes. Pay close attention to your measurements, secure everything firmly, and always prioritize safety. Your track saw is more versatile than you might have thought, and mastering resawing is a testament to its incredible utility in the modern workshop.

So, grab that beautiful board you’ve been saving, set up your track, and get ready to unlock its full potential. You’