Plastic laminate shows up in all kinds of woodworking projects, from workbench tops and shop fixtures to cabinets and furniture. And when you need to break down a large sheet, the table saw can make quick work of the job while leaving a clean, straight edge.
There is one problem, though. Plastic laminate is extremely thin. On many table saws, there’s just enough clearance between the bottom of the rip fence and the saw table for the edge of the laminate to slip underneath.
If that happens while you’re making a cut, the laminate can shift or get cocked against the fence. At best, you end up with a poor cut or a damaged sheet. More importantly, you can lose control of the workpiece.
Fortunately, there’s a simple fix.
The Problem with Cutting Thin Laminate
A standard rip fence works great with lumber and sheet goods because they’re thick enough to register solidly against the face of the fence. Plastic laminate is another story.
As you feed a large, flexible sheet through the saw, its edge can find the small gap underneath the fence. Once it starts slipping underneath, keeping the sheet moving straight becomes difficult.
The solution is to eliminate that gap and give the laminate a continuous surface to ride against.
Add an Aluminum Angle to the Table Saw Fence
All you need is a straight piece of aluminum angle and a couple of clamps.
Position the aluminum angle along the bottom edge of the rip fence with one leg resting flat on the saw table. Then clamp it securely to the fence.
The horizontal leg bridges the gap underneath the fence and creates a smooth surface for the thin edge of the laminate.
A Smooth Path for the Laminate
Now when you position the laminate against the fence, its edge rides on top of the aluminum angle rather than trying to work its way underneath the fence.
The result is a more consistent reference surface that makes a large sheet of laminate easier to guide through the cut.
Before making the cut, make sure the aluminum angle and clamps are secure and positioned so they won’t interfere with the blade or the workpiece.
A Simple Table Saw Tip for Better Laminate Cuts
This is one of those shop solutions that doesn’t require an elaborate jig. A scrap of aluminum angle and two clamps are enough to turn your existing rip fence into a better guide for cutting thin plastic laminate.
The setup keeps the laminate from slipping underneath the fence, gives you better control over the sheet, and helps produce a cleaner, straighter cut.
If you regularly use plastic laminate for woodworking projects, it’s a quick table saw trick worth keeping in mind.
Learn More About Working with Plastic Laminate
Want more detail on choosing vertical- or horizontal-grade laminate, MDF vs. plywood substrates, contact cement, flush-trim and bevel-trim router bits, and filing the finished edges?
Our complete guide walks through the entire process.
HOW TO WORK WITH PLASTIC LAMINATE → How to Work with Plastic Laminate: Cutting, Gluing & Trimming
