Smooth straight cuts in MDF?

[rhoelsch]

Ok, I need to buy something to cut my MDF (cp and cab), and was wondering who got great or poor results with the following tools:

1.  Circular Saw- figure carbide-tipped with as many teeth as possible would do the trick...right?  

2.  Jig saw-- have a cheap B&D, but I had trouble getting thru plywood with it, and my line was all over the place...

3.  Router- never used one; rather clueless about 'em and how well they might work

4.  Anything else I haven't thought of...

Oh, and did I mention I'd like to do this rather cheaply?  I'm concerned about getting a nice smooth cut first, but I also need to make sure my cuts will be straight!  And before you ask, the power tools guy at Depot was pretty "out there"; not to mention he didn't know what MDF was :{

Thanks!

[Distortion]

I did my entire thing with a jigsaw.  I don't recommend this, but if you must, do what I did.  Leave some extra room, then sand it down with a power sander and 40 grade sandpaper so that it's nice and straight.  Worked pretty well for me.

[dash213]

the best way would be with a router, you would not even have to sand!!  just make sue u clamp a straight edge on the work piece before routing.

[GearHead]

Go with a table saw with a carbide tipped blade that's designed to cut MDF.  MDF is very different than wood or wood laminates and handles differently because of its composition, its density and its thermo dynamic properties.  It'll create some fairly nasty dust & go through blades faster than wood too.  See if you can find a local cabinet shop/kitchen counter shop that will cut things for you.  Maybe not cheap but it will save you lots of frustration.

If there's no table saw available use a circular saw with the right blade.  A 40 tooth, carbide tipped blade should be ok.  Check the manufacturer's specs on the blade.  You can buy long straight edges or saw guides to make straight cuts.  How fast you make the cut will affect the edge too.

Jigsaws - avoid them if possible.  If you had trouble with plywood you'll have more trouble with MDF.  The blades are not meant for MDF and they tend to bend and warp when they get dull and heat up.  Little blade and big cut - not a good combo.

A router?  yikes no! You can finish an edge with a router but don't make long cuts with it.  You'll end up burning up lots of bits and creating a lot of heat.  Use a saw to cut, that's why they make 'em.

MDF contains urea formaldehyde so use a mask and cut the stuff in a well ventilated area.

[GSXRMovistar]

I didn't have much in the way of power tools when i started my build, just a multi-function drill/saw combo. Completely useless for nice straight cuts, so i invested in a router as knew i it would be needed for various jobs.

I used the jigsaw to make the cuts, allowing 1-5mm outside my cut line as it was impossible to make a straight cut with this. Once cut i used a straight edge (anything long straight and stiff) clamped this along side my cut MDF and ran the router along it to get a straight finish. Had great results using this method and the router only cost me

[Brax]

A circular saw with a good blade and a straight edge can give you comparable results to a table saw. It's a good all-around choice.

[hyiu]

ok... one of your concern is do this cheaply... right ??

you said you have a jigsaw....

good.... if you're willing to invest.... go get good jigsaw blades.... (I think HD has those "Bosch" blades for jigsaw...), anyway... ask and get the good one (for wood / MDF).... then go get a BIG LONG METAL RULER.... and a few clamps...

blades are less than $10 a pack.... clamps are like $2 each... ruler should be less than $10 or so......

then you measure..... and clamp the ruler down with the clamps.... and use the ruler as the guide to your jigsaw....
now.... don't push your jigsaw when cutting..... (well.... don't force it... let the blade do its job...) and you should get good straight cuts....

this might be cheaper than getting a new circular saw with good carbide blades....

good luck....

[pocketz]

i use a circular saw and these things called tool guides. tool guides are straight edges that clamp down on the wood and create a sturdy guide for the saw, straight cuts every time. you can also use a straight 2x4 held onto the mdf with two clamps. mdf is easy to sculpt with a sander so if the cut isnt perfectly straight just sand it down.

-pocketz

[Wade]

I was almost finished with my cabinet when I finally figured out the best combo for cutting MDF.

Jigsaw - avoid when possible.

Circular saw with MDF blade (about $15).  Worked horribly.  Blade was dull after one cut.

Circular saw with cheap (included with $35 saw!) 22 tooth rough cut blade.  Worked well but was dull after perhaps 10 cuts.  Also tended to flex or "walk" so some of my cuts weren't perfectly straight with this blade.

Circular saw with a quality Carbide 22 tooth blade (about $12).  That's it!  My cuts are perfect every time now.  Sanding is RARELY necessary.  I would have saved myself HOURS and lots of scrap wood too if I had known this from the start.

Wade

[ZaneMn]

 If it is within your budget you should get a table saw:  Not only wil it make great straight cuts but it will make sure all of your cuts are consistent.  What do I mean by that?  It means when you are cutting out all the sides for your control panel with a table saw you don't run the risk of getting slightly diffrent heights on the pieces as you might if you did each one with a circular saw. The fence on a table saw is great!

[mpm32]

If you don't see yourself doing much woodworking after your cab, why don't you go to a rental place and rent the tools you need.  Most rental places will have better quality tools than you can buy cheaply.

[rhoelsch]

Ok, so the leader seems to be circular saw w/ carbide blade and a straight edge.  I'll use the jig to cut the hole for my coin door (or should I still invest in a router?).  Guess I'll get a circular saw that can angle 45 deg. for mitred corners fitting together...but then again, I'll have to get something to cut slots for the T-molding, probably look into renting a router...

Thank you boys.......Thank you