The Basics: Power Saws

Remember Tim "The Tool Man" Taylor's "more power!" shtick? Well, ABC pulled "Home Improvement's" plug back in 1999, but America's love affair with power tools has never been stronger. These days, though, it's not just about the RPMs. Manufacturers are delivering more efficient motors, but they're also focusing on features that are just as important to users of all skill levels. When it comes to one of the most popular subcategories of power tools -- power saws -- those features include everything from ergonomic grips and easy-to-operate controls to precisely aligned blades and safety mechanisms. Today, power saws offer a whole lot more than just power.

Power saws, whether they're circular saws or jigsaws, are extremely popular with both professionals and amateurs. If you do any amount of construction or woodworking, we recommend investing in one of each. Combined, they'll let you tackle tasks as diverse as slicing through lumber to build a deck and cutting ornate patterns in a piece of furniture.

At first glance, the hundreds of circular saws on the market may all look alike, but dig a little deeper, and you will see that they've each got specific -- and sometimes minor -- design or performance features that set them apart. Each model may offer different advantages and challenges, but they're all designed with one purpose in mind: to chew through wood. (With the right blade, you can also cut ceramic tile, steel or masonry.) Circular saws are the workhorses of the power saw world, single-minded and efficient.

Jigsaws, on the other hand, are more versatile and lightweight. The handheld tools are a basic element of most workshops, and can be used to make cross-cuts, plunge cuts, beveled or mitered cuts or freestyle scrolling cuts. Jigsaws can tackle many of the tasks that a circular saw handles, just not as well. If you often alternate between different materials, consider a jigsaw that uses an easy-to-adjust setting to accommodate thin and thick, or hard wood, metal or plastic.

How to Shop

Circular saws have two main uses: cross-cutting and ripping. Cross-cutting is when you slice across a piece of lumber; ripping is when you saw with the grain, usually though a flat piece of plywood. Any circular saw should be able to accomplish either of these tasks without much trouble; where they will differ is in the design. Some pros swear by a worm-drive design, which positions the motor in line with the blade. Worm-drive saws deliver impressive amounts of power -- hence the contractors' propensity to choose them -- but they're also heavier and cost more. A more popular option, especially for homeowners, is the sidewinder design. This is the one that springs to mind when you think of a circular saw. The blade on this type of saw is attached directly by a shaft to the motor. They're cheaper, lighter and easier to operate than worm drives.

Jigsaws are smaller tools, and work well cutting thinner material, usually up to 1-1/2 inches thick. They work by driving a vertical blade up and down, and cut by pulling upward. Most jigsaws let you easily switch between different blades to better accommodate different materials.

Manufacturers are devoting plenty of resources and attention to design, from the tip of the handle to the bottom of the saw's base (also known as the shoe). The handle on a sidewinder circular saw can be either a pistol-grip design or a bail handle, which lets you grip a horizontal bar. Most handles are non-movable, but ergonomic features such as adjustable handles are popping up on a few models, which let the user adjust the saw to their posture, rather than the other way around. Jigsaws usually employ a pistol-grip design, with varying levels of padding and trigger size. Many have a secondary handle, too, which makes it easier to keep a good amount of control while you cut.

A saw's blade is one of its most important elements. With a circular saw, invest in the best blade you can afford; the more teeth, the smoother the cut. A typical heavy-duty circular saw uses a 24-tooth, 7-1/4-inch blade, but we've seen cheaper models come with much less effective 18-tooth blades. Steel blades are the least expensive, but they tend to dull pretty easily when used on hard wood. Carbide-tipped teeth stay sharper much longer. Look for a circular saw with a shaft or spindle lock to make blade changing a breeze. The lock keeps the shaft and blade from moving, which makes it easy to change.

On jigsaws, even the cheapest units these days feature a tool-free blade changing system. But some of the better models also come equipped with the next level of blade-changing simplicity: a system that lets you pop out the blade without touching it, so you don't have to work about burning your fingers on a hot blade, or cutting them on a broken one.

Accuracy is king when it comes to saw performance, and many of today's circular saws -- even inexpensive models -- come equipped with an onboard laser to help ensure accurate cuts. The laser shoots out a bright, high-intensity beam, which can make all the difference when you're trying to follow a smudged pencil line or a piece of plywood that's covered in sawdust. Lasers are much more useful on a long ripping job (you will need less help when you're cross-cutting a short piece of lumber), but can be not as visible outdoors in direct sunlight. Believe it or not, even some jigsaws on the market today come with a laser.

Another important gauge of accuracy is how square the saw base is to the blade. Most circular saws allow you to fine-tune the angle to set a perfectly precise cut.

Regardless of whether you're talking about a circular saw or a jigsaw, one of the biggest decisions you will need to make is about your tool's power source. Both tools are available in electric- or battery-powered versions. Corded models are often more powerful than their cordless counterparts, and deliver more torque. Cords come in various lengths -- we've seen them as stubby as 6 feet, or as long as 15 feet. When you're taking cord length into consideration, keep in mind how and where you will be using the saw and how much elbow room you will need. Most models come with a 10- or 12-foot cord, which is plenty.

If you're worried about slicing your tool's blade through its cord (don't laugh, it happens), or simply prefer a more portable unit, consider a cordless model. These days, advances in battery design are allowing tools that were once bulky and tethered to a cord to reach new levels of portability. Rechargeable 18-volt batteries started the movement toward smaller, easily interchangeable power sources; the latest is lithium-ion technology, which can last up to 40 percent longer than 18-volt batteries.

Some batteries take hours and hours to recharge; others can be rejuvenated in as little as an hour. We recommend purchasing an extra battery -- or buying a saw that comes with two -- so you can always have one on the charger. Several manufacturers are unveiling entire lines of tools that run on a single, interchangeable battery. You can take it off your circular saw and pop it onto your jigsaw, for instance.

If you're only going to use your saw occasionally or on smaller jobs, a cordless tool should work just fine. For real, professional-grade power, though, you will want to stick to corded units.

Durability is another consideration. Look for a well-made tool, with impact-resistant housing. An aluminum shoe at the base of a saw can bend if you drop it. A cast-metal shoe is more durable, but adds weight.

Safety is a huge consideration for any power tool, but it's especially important with saws. Look for a model that incorporates several safety features, including a trigger lock to prevent accidental starting or a blade brake that instantly stops the blade from moving the split second you take your finger off the trigger.