Cutting the sides

[EssexMame]

All projects appear to cut the 2 sides of the cabinet separately.

Why is this? Would it not guarantee they match if they are cut together, one on top of the other. Then, even if the cut is off the plan they would still match and you'd not need to make adjustments.

I'm a wood cutting newbie, so I realise there is probably a simple reason why its not done like that - but why is that?

[Dekieon]

One side is cut first using what ever tools you choose to get your desired shape cut and ready. The side that you just cut is them clamped onto another sheet and it cut using a router with a flush trim bit. This makes and exact copy of the first one you cut.

If you would try and cut them both at the same time it would be hard to do, plus if you made a mistake you would be making it on two pieces instead of just the one piece.

[shponglefan]

One side is cut first using what ever tools you choose to get your desired shape cut and ready. The side that you just cut is them clamped onto another sheet and it cut using a router with a flush trim bit. This makes and exact copy of the first one you cut.

+1

[JDFan]

+1 -- Plus if using a jigsaw for the angles the blades tend to bend a bit instead of staying at 90 degrees and any angling\warping of the blade as it was cutting would be even more pronounced on the bottom piece making you sand even more to get the 2 pieces to match. 

[Drnick]

And on top of the above, If you mess it up and or change your design, you're at the worst 1 piece of MDF down 

[kahlid74]

+1 -- Plus if using a jigsaw for the angles the blades tend to bend a bit instead of staying at 90 degrees and any angling\warping of the blade as it was cutting would be even more pronounced on the bottom piece making you sand even more to get the 2 pieces to match.

If you're cutting straight lines you could cut both at the same time with a saw board and a good 8-10" circular saw but what JDFan says here is money.  Trying to cut two sheets with a jig saw will leave uneven cuts and all sorts of things that will have you scratching your head.

As everyone else said above, cut the first piece to what you want.  Clamp the two together and use a jig saw to get the second piece to within a 1/4" of the first.  Then use a router flush trim bit to make them match perfectly.

[EssexMame]

Thanks to all.

I'm planning on getting a router, it crops up a LOT, so I'll get a flush bit.

I've built a saw board over the weekend so I will use this to get straight cuts on both sides. Hopefully then the flush bit and sanding will fix any (hopefully small) differences between the two sides!

Not sure what my (borrowed) circular saw is, but it could probably cut through two sheets. Even so, I'll do it separately as that seems to be the common advice above, thanks.

[Sparkolicious]

I use my router with a straight edge similar to the straight edge (saw board) I use with my circular saw. By similar, I mean exactly the same lol! It leaves a cleaner edge on that first panel/template, and that is just how I roll.

[ebarlow99]

I use a laser to cut my sides precise cuts and both sides are identical!!!...If your not good with woodworking let me know I can cut you some

[spratkobasa]

I was wondering how can you check to see if all the cuts where 90 degrees and not angled?

Also if you have some angling or warping how do you fix it? (Just sand it down prior to using the template bit to make the otherside?)

[Drnick]

I was wondering how can you check to see if all the cuts where 90 degrees and not angled?

Also if you have some angling or warping how do you fix it? (Just sand it down prior to using the template bit to make the otherside?)

Use a T-square to check that everything is 90 Degrees. Yes you should sand down and tidy up before duplicating.

[kahlid74]

I was wondering how can you check to see if all the cuts where 90 degrees and not angled?

Also if you have some angling or warping how do you fix it? (Just sand it down prior to using the template bit to make the otherside?)

Use a T-square to check that everything is 90 Degrees. Yes you should sand down and tidy up before duplicating.

And you should make sure it's what you want.  Take a step back after touching it up and make sure it's what you want.

[spratkobasa]

Thanks guys! I made sure my first piece was perfect now I have to use my router for the first time to cut the second piece.  How can I help make sure I keep the router flat and should I take multiple passes to cut through the 3/4 inches of MDF?

Also I clamped the two pieces together should they be clamped to something else so that it doesn't move, or is the piece big enough I don't have to worry (it's 29 x 85 inches)

[michelevit]

When I cut the second side, I lay the first side on top of it, trace it with a thin sharpie and then use a skill saw or jig saw to cut to that line. I then clamp and use a router with a bearing bit to cut up to the line using the first side as a guide.

Multiple passes for sure. Get someone to hold a shop vac nozzle at the base of the router. Cutting MDF makes a tornado of dust.

I'd use a couple of simple wood clamps to clamp both pieces together and make sure they dont slip.

[spratkobasa]

Thanks michelevit.  I had it all clamped and now I have two exact sides thanks for the advice.  I had the vacuum going but it couldn't grab everything. Warning to others try to do this outside and not in a garage.