Tips for Using Every Square Inch of Plywood

Set Up a Cutting Plan

Start with laying out your project on graph paper, a 3D modeling program like Sketchup or a cut-optimizer app, so you can efficiently plan how to nest pieces together to minimize waste. Next, map that onto your plywood sheet with a pencil or cardboard stencil, accounting for the 1/8” of material the saw will remove (aka blade kerf).

Pro-tip: Grain direction matters. “We used to optimize for material savings, but now we cut with grain direction in mind first, and packing the cuts tighter second,” says remodeler Todd Cechini. “Counterintuitively, we actually get more usable scraps this way because they’re oriented correctly for future drawer fronts or small panels.”

Optimize Cutting Technique

Cut the largest pieces from the sheet first. “This will keep it more stable and manageable, to help preserve clean, usable offcuts for smaller parts later on,” says professional organizer Christina Giaquinto.

Properly support the sheet while cutting, to prevent flexing, binding and splintering. If you’re worried about freehanding cuts using a jig or circular saw, DIY enthusiast Rusty Meador recommends building a straight-edge jig. “A wavy line messes up the cut, and the cut on the next edge, and before you know it, your whole plan is thrown off,” he says. “Plan a little, slow down your cuts.”

Keep the Blade Sharp

A sharp, fine-tooth blade that’s designed for cutting plywood will minimize tearing and uneven cuts. “It’s not different than cutting veggies in your kitchen,” says roofer Mike Feazel. “A dull blade frays edges and forces you to trim things down after the fact.”

Safety tip: When cutting plywood, always wear safety glasses and protective hand and footwear.

Protect the Edges

To keep plywood from splintering, place a piece of masking or painters’ tape directly over the line you want to cut. “This will keep the wood from splintering, and you will end up with a nice, smooth cut,” says builder Anthony Shirk.

For off-cuts that don’t match the sides and top, remodeler Zachary Smith recommends adding iron-on veneer tape. “It delivers professional coverage at a fraction of the cost,” he says.

Pro-tip: Use a sharp chisel and cut excess tape with the grain to avoid it tearing out.

Consider a Router

Using a router helps minimize splinters and mis-cuts. While they’re not always practical, Shirk finds them invaluable in situations such as cutting excess plywood from door frames.

Fasten your plywood to the surface you are mounting it to, then use a router with a down-cut spiral bit to remove the excess plywood, says Shirk. “These bits leave a perfectly cut edge that is perfectly even with the edge of your frame. We then use the cut-off pieces for material on the structure’s roof overhangs.”

Layer Pieces

If you need a thicker or stronger panel, layer thinner sheets of plywood rather than buying an expensive thick board, says realtor Ryan Fitzgerald. “Gluing two sheets can provide a strong panel for cabinets, shelving or worktops, while also conserving material and being very cost-effective.”

Evenly spread the glue, then clamp the panels firmly until the adhesive sets. To prevent spots, clean up excess glue before it dries. Once cured, sand both sides together to ensure the thickness is uniform. “Take your time in alignment of the sheets and use steady pressure for the best results,” says Fitzgerald.

Save the Scraps

Nearly every bit of scrap plywood is usable for some sort of project: think edge banding, cleats, shims for leveling furniture, a push stick for your table saw, garden bed edging and drawer dividers. As a kid, Shirk even used small strips to create rubber band guns.

“My wife doesn’t like it, but I rarely throw out anything wider than 1.5 inches,” says Feazel. “It always comes in handy later for DIY projects!”

About the Experts

• Mike Feazel is CEO of Roof Maxx and has been in the roofing and construction industry for more than 30 years.
• Anthony Shirk is operations manager at Sunrise Structures, an Indiana-based shed builder.
• Todd Cechini runs Dun-Rite Home Improvements, Inc., a four-decade-old Colorado home remodeling company.
• Zachary Smith is the founder and CEO of Ready House Buyer in Dallas, Texas, which has rehabbed more than 100 houses in the past seven years.
• Rusty Meador is the founder of Beach & Barn, a coastal menswear brand based out of Wilmington, NC, which began as a carpentry and restoration company. He is host of WaveFarm Podcast.
• Ryan Fitzgerald is a realtor, home expert and the owner of Raleigh Realty in North Carolina.
• Christina Giaquinto is a professional organizer and brand ambassador of Modular Closets, which makes customizable DIY home closet units.
• Curran Clark is co-founder of ContractorNerd, an insurance agency for contractors.

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