While standard circular saws are great for most lumber, they often fall short for thicker stock. If the wood is deeper than your saw’s blade depth, that’s a problem. Cutting large timber can be a challenge even for experienced woodworkers, so it’s important to know the right way to do it. In this guide, we’ll show you step-by-step instructions on how to get clean, straight cuts on big timbers every time.
Understanding the Challenges of Big Timbers
Big timbers, like 4-by-4 posts and 6-by-6 landscape timbers, can be tricky to cut if you’ve never done it before. Their thickness exceeds the cutting depth of standard circular saws, which typically max out at about 2 1/2 inches. That means that you’ll have to make multiple passes to get straight, clean cuts.
To cut these larger pieces of wood, you’ll need to use a combination of circular saws and handsaws. When done correctly, this method is an easy way to get a precise cut on big timbers.
Essential Tools for Cutting Big Timbers
Before you begin, make sure you have the following tools:
- Circular Saw: This will make the initial cuts in your timber.
- Handsaw: You’ll use this to finish the cut when the circular saw blade can’t reach deep enough.
- Speed Square: This serves as both a marking tool and a guide for your saw, keeping your cuts straight.
Step-by-Step Guide to Cutting Big Timbers
Now that you have your tools, it’s time to start cutting. Follow the steps below carefully for the best results.
Making the First Cut
- Mark the cut line on one face of the post using the speed square to guide the pencil.
- Place the saw’s shoe flat on this face and line up the blade with the cut line.
- Hook the speed square on the corner of the post and slide it against the shoe.
- Hold the square tight and pull the saw away from the wood slightly, then pull the trigger on the circular saw.
- Make the cut using the edge of the square to guide the saw in a straight line.
Rotating and Continuing the Cut
- Rotate the post toward you.
- Place the stopped blade in the kerf (the cut mark you just made).
- Put the square against the saw’s shoe.
- Hold the square tight, pull the blade out of the kerf, then pull the trigger and make the cut using the edge of the square as a guide.
- Rotate the post toward you again. Repeat this step to continue cutting through the timber.
Finishing the Cut on Larger Timbers
For timbers larger than 4-by-4:
- Rotate the timber toward you once more.
- Set the circular saw blade in the kerf and make a fourth cut as before.
- Take a handsaw or a reciprocating saw with a long blade.
- Cut through the untouched wood at the center of the timber, using the kerfs as guides for your blade. With a long blade, you can complete the full cut.
Safety Precautions When Cutting Large Timbers
Working with power tools can be risky, so it’s important to follow safety measures to protect yourself from potential hazards. Here are some safety tips to keep in mind.
Personal Protective Equipment
Always wear appropriate personal protective equipment (PPE) when cutting big timbers. This includes:
- Safety glasses or goggles to protect your eyes from sawdust and debris
- Ear protection to guard against the loud noise of power tools
- Work gloves to improve grip and protect your hands
- A dust mask to prevent inhalation of sawdust
Before cutting, make sure your PPE fits properly and doesn’t leave any gaps.
Timber Support and Stability
Proper support is key to getting a clean cut and preventing the timber from shifting. Use sawhorses or a sturdy workbench to support your timber. If possible, have a helper hold the timber steady as you make the cut.
For more instructions and safety measures, refer to the Occupational Safety and Health Administration (OSHA) Guide for Protecting Workers From Woodworking Hazards.
Troubleshooting Common Issues With Big Timbers
Even with the right tools and techniques, you may run into some challenges when cutting big timbers. Here’s how to address a few common issues.
Dealing With Blade Binding
Blade binding happens when the wood pinches the saw blade, stopping its rotation. To prevent this:
- Make sure to support the timber on both sides of the cut properly.
- Use a slightly wider kerf blade.
- Apply steady, even pressure while cutting.
If the blade binds, release the trigger immediately and carefully remove the saw. Realign your timber before resuming the cut.
Correcting Mid-Cut Deviations
If you notice your cut veering off course:
- Stop cutting immediately.
- Retrace your cut line.
- Use your speed square to realign the saw.
- Continue cutting, paying close attention to your guide and cut line.
If you’re getting a lot of mid-cut deviations, you may be rushing your work. Take your time and work carefully for the best results.
Additional Methods for Cutting Big Timbers
While the circular saw method is effective for most situations, it’s not the only way to cut large timbers. If it doesn’t suit your needs, there are other tools that can help you cut large timbers.
Using a Chainsaw
For very large timbers that don’t need a precise cut, a chainsaw is an effective tool. It offers greater cutting depth, but it may not give you a clean cut. You may need to sand or plane the timber afterward to smooth out the cut.
Using a Band Saw
In workshop environments, a large band saw can make clean, straight cuts through big timbers. Though it’s less portable than other options, a band saw provides precision and allows you to cut curves if necessary.