What Is a Flush Cut Saw? Uses, Tips, & Maintenance
What is a Flush Cut Saw?
The Flush Cut Saw is a specialized saw designed to neatly finish the surface and joints of wood. It is primarily used for cutting dowels and wooden pegs, and its teeth have no set, making it less likely to damage the surface.
Due to these characteristics, it is an ideal tool for precise work, such as crafting and furniture making. In Japanese, it is also referred to as a "Dabo Kiri Nokogiri" (dowel cutting saw) or "Asari-nashi Nokogiri" (saw without set).
Features and Benefits of the Flush Cut Saw
Saw Blade Without Set Teeth
Unlike most saws, which have set teeth (where the edges are bent outward to help expel sawdust and make the cutting process smoother), the flush cut saw has teeth that are straight. While this makes the saw slower, it also reduces the risk of damaging the wood surface, resulting in a cleaner, more precise cut.
Because the blade is less likely to damage the surface, you can position it flush with the wood for a smooth, even cut. Plus, with a cleaner cut, you'll spend less time on post-processing, like sanding.
The blade is thin and flexible, allowing it to follow the wood's surface closely for a controlled, accurate cut.
Check out our collection of Flush Cut Saws
The Flush Cut Saw's Intended Use
This tool is designed for cutting dowels or wooden pegs flush with the wood surface, allowing you to achieve a smooth, level finish.
Wooden pegs and dowels are both essential in woodworking, but they serve different purposes. Wooden pegs have a tapered shape, allowing them to securely hold pieces of wood together by driving them directly into the material.
In contrast, dowels are cylindrical and are primarily used to conceal screws for a cleaner, more polished appearance. Dowels are often used in conjunction with screws, which means the holes are larger and deeper to accommodate both, whereas wooden pegs can be driven in with smaller, more precise holes.
How to Cut Dowels and Hide Screws
1. First, drill a hole for the dowel where the screws will be joined.
2. Insert the screws to secure the pieces together.
3. To make the hole more receptive and ensure a secure fit, lightly tap the side where the dowel will be inserted with a hammer. This technique, known as "wood killing," helps the dowel slide in more easily and stay firmly in place.
4. Apply adhesive to the hole.
5. Insert the dowel into the hole and tap it in with a hammer.
6. (After wiping off any excess adhesive,) use the flush cut saw to cut the protruding part of the dowel so it aligns with the wood surface.
7. Finish the surface flush using a plane or sandpaper.
Why Hide Screws?
In furniture making, such as drawers, chairs, and tables, screws are hidden to give the piece a cleaner, more aesthetically pleasing finish. Since the dowel is made from wood of the same type as the surface, it can be planed to achieve a more natural and beautiful finish.
Important Considerations for Dowel Joints
When using dowels, it's essential to securely attach them with adhesive, which means once they’re in place, the joint can't easily be disassembled, such as by removing screws. This makes disposal or repairs something to consider carefully.
Additionally, because dowels and screws require a certain depth for proper fitting, the wood needs to have a sufficient thickness to accommodate the joints.
How to Use a Flush Cut Saw
The Basics: Use it for Cutting Dowels
To ensure the blade closely follows the surface of the wood, press the saw blade while sliding it along the area you wish to cut.
Tip for Beginners: Lightly press the blade with your fingers while moving it gradually. It’s important not to apply too much force so that you can easily control the movement of the blade and glide it smoothly along the surface of the wood.
Mind the Level of the Cut
Position the flush cut saw's blade so that it stays flush with the wood's surface.
Gently press the blade with your fingers and carefully slide it along the wood. If the blade is angled, it can dig into the surface, causing damage, or it can leave too much of the dowel behind, resulting in an uneven finish. To avoid this, make sure the blade remains level with the surface for a clean, smooth cut.
Keep the saw level and continue cutting until the dowel is fully separated from the wood.
Key Points for Choosing a Flush Cut Saw
Important Factors to Consider When Selecting a Product
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Blade Shape - A finer tooth pattern results in a cleaner cut.
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Flexibility - Blades that are more flexible make it easier to follow the surface of the wood.
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Length and Size - This product is specifically designed for dowel cutting, so it comes in a shorter and smaller size to make dowel cutting easier.
Points to Consider Before Purchase (Beginners)
The flush cut saw is a tool specialized for cutting dowels and wooden pegs. It is not suitable for general purposes like a regular saw.
Other small-sized craft saws may have a similar shape. When choosing a flush cut saw, be sure to check whether it has set teeth or not before purchasing.
Differences Between the Flush Cut Saw and Craft Saws
Both the flush cut saw and craft saw are valuable tools in woodworking, but they serve different purposes and have distinct designs. The comparison table below highlights the key differences between the two, helping you choose the right tool for your specific needs.
If you're unsure about how to choose the right saw, please refer to the guide below to help you find the perfect one for your needs.
How to Choose a Japanese Saw by Type: The Kakuri Difference
Precautions When Using a Flush Cut Saw
Be careful not to damage the surrounding wood.
If the blade enters at an angle, it can damage the wood surface. It is important to keep the blade flush with the surface of the wood and maintain a level cut.
Since there is no set, there is more friction between the blade and the wood, making the cut heavier and taking more time. The blade is thin and flexible, so it is prone to bending (or flexing). If the blade is not kept straight, it can get stuck and stop moving.
Use it As Intended
Due to the short cutting width, it is not suitable for thick materials. It is specifically designed for cutting dowels and finishing surfaces, so it is not suitable for general cutting tasks.
Be Careful When Handling the Blade
The blade is very thin and delicate. Dropping it or applying excessive force can cause it to bend or break. Especially during storage, be sure to keep the blade in a protective case or container to prevent exposure and store it in a safe place.
Maintenance and Care
Post-Use Care
Rust Prevention
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After use, remove sawdust with a brush and wipe the blade with a cloth soaked in rust-preventive oil. This helps prevent rust and extend the lifespan of the blade.
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If sweat or moisture comes into contact with the blade, wipe it thoroughly with a dry cloth. Moisture can cause rust.
Storage
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Avoid storing the saw in hot or humid environments. Keep it in a dry place. Wrapping the blade in rust-preventive paper or newspaper can further help prevent rust.
Tips for Prolonging its Lifespan
Good maintenance can ensure your flush cut saw remains in top performance condition. Follow these care and usage tips to keep your tool sharp and functional for a long time.
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Use as Intended: The flush cut saw is not designed for thick, hard materials or metals, as it can clog and has lower durability.
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Avoid Excessive Force: The blade is thin and flexible, so use light pressure to prevent bending, breaking, or chipping.
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Keep Dry: Do not use on green or wet wood to avoid rust and clogging from moisture or resin.
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Post-Use Care: Clean the blade regularly with a brush to prevent buildup that can reduce efficiency and cause damage.
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Prevent Rust: Wipe the blade with rust-preventive oil and store it in rust-preventive paper or newspaper.
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Protect the Blade: Store the saw in a case or cover to avoid contact with other tools and prevent chipping.
Best Flush Cut Saw Products and Reviews
Kakuri flush cut saws are made in Japan, highly rated, and are known for their superior quality and durability. The blades are crafted from high-quality Japanese materials, and the handle is made from red oak, ensuring a comfortable grip and excellent finish.
These saws feature replaceable blades, making maintenance easy. The cutting performance is highly praised, with users describing the blades as "incredibly sharp, well-sized, and leaving a smooth finish... like a hot knife."
Each saw set comes with a dedicated cloth bag, allowing for safe and convenient transport.
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Hand Saw -Red Oak Handle -Flush Cut 180mm |
Recommended Flush Cut Saw for Beginners
Conclusion
Using a flush cut saw allows you to achieve beautiful finishing work. Since the cutting surface is less likely to be damaged, it is ideal for tasks that require a clean finish. It is suitable for both professionals and DIYers alike.
With proper use and care, your flush cut saw will provide lasting performance for years to come.
Collections to Check Alongside the Flush Cut Saw
・Wooden Nails
・Small Genno Hammer - Ryoguchi 185g
・Mini Plane -Flat -Ebony Body 18mm
