Angle Cut Grilles
Today, we’re going to be discussing angle cuts for an 1100 Cross Piece Grille. Square cut ends and angle cuts are very similar, but with a few key measuring differences and some other things we need to think about.
What tools do I need?
Regarding the tools you are going to need, we’ve shown everything you’re going to need here. In particular, make sure you have a 7-1/4” Circular saw equipped with a 40–60 tooth blade like the Dewalt 3196. Or you can go with a variable speed jig with a reverse-cut blade like this Bosch BR101.
We know that job sites can be tricky when it comes to finding a location to do your cutting, but make sure that you have found a safe location where you can do fine detail work.
What to do first?
The first step is to measure the area where the panel is going to be installed. Ensure that you have the angle correct and the long point and short point of either side of the panel to make sure your cut is going to be accurate. We also use the digital level and angle finder to verify the angle of the finished cut.
Once you determine the length of your panel, you’re going to want to cut it to length first, if applicable, to ensure you have the angle in the right location. You can look at our square-cut end video for more information.
What if there is a backer?
If there is a backer where the panel needs to be cut, flip the panel over and remove it with a pry bar. Ensure that all staples have been taken out as well.
Measure and mark
Once the length of the panel has been set correctly, you’re going to measure from the opposite end at your short point mark and your long point mark. Once the marks have been made, you’re going to cover the area with painters’ tape, razor-knife it, and cover those areas like I have shown before.
You’re then going to remeasure and mark the short point and the long point on your panel and verify that the angle is correct. Mark that with your square and get ready for your cut.
How do you prepare your saw?
You’re going to want to make sure you set the depth of your saw so that you cut cleanly through all of the members without any issues.
As you begin your cut, it’s important that you stay consistent in speed through the entire panel, from member to member, and that you don’t stop or slow down. This ensures that you don’t have tear-out or any problems with the next piece as you cut through one entirely.
What if there are uncut members?
If you have members that are not supposed to be cut at the end of the panel and you used the circular saw, you might have to use a hand tool, such as a Japanese hand saw, to finish up that last member to ensure that it has a nice clean edge when you’re done.
For proper suspension and member alignment, extra backers may need to be reattached. Contact your project manager for specific requirements. Upon completion of your cut, check the angle, remove the tape, and sand off any fibers you may have left behind while you were cutting.
Seal ends completely
Your final step is using 9Wood’s provided touch-up finish to touch up the ends with the proper color and then you’re ready to dry-fit your panel and make sure it fits.
If you have any questions about field cutting or would like to talk about details specific to your project, please contact 9Wood and we’ll put you in touch with the right person. As always, thank you for watching and we’ll see you next time.
- Tape Measure
- 48″ Straight Edge
- 16″ Framing Square
- Bosch Digital Level/Angle finder
- #2 Ticonderoga Pencil
- 2″ 3m, or equivalent, Yellow Painters Tape
- Pry bar
Finish and touch-up items
- Matching Stain (provided)
- Water-Based Lacquer (provided)
- Sponge Brush or rag (childhood T-shirts for posterity)
- 7 1/4″ Circular Saw equipped with a 40 to 60 Tooth blade.
- Variable Speed “Jig Saw” equipped with a reverse cut blade.
- Example: Bosch Blade T101BR
- Cordless Drill with side handle
- Appropriate hole saw arbor (1/2″ was used in our video)
- Appropriate diameter Bi-Metal Hole saw (4 1/4″ was used in our video)
- Japanese Pull Saw (for finish cuts where power tools cannot access)