Resaw Explained: Woodcutting Technique For Perfect Boards (Pro Tips)

Let’s dive into the art and science of resawing, a technique I’ve come to know intimately after years spent in the woodshops of the Pacific Northwest. Resawing isn’t just about slicing a board thinner; it’s about unlocking the hidden potential within a piece of wood, revealing its grain, and creating materials perfectly suited for your projects. Whether you’re crafting delicate inlays, building lightweight furniture, or simply trying to maximize your lumber yield, mastering resawing will open up a whole new world of possibilities.

Resaw Explained: Woodcutting Technique for Perfect Boards (Pro Tips)

What is Resawing?

Resawing, at its core, is the process of cutting a board along its thickness to create thinner boards. Imagine taking a 4/4 (one-inch thick) plank and slicing it in half to get two roughly 3/8-inch thick pieces. That’s resawing in a nutshell. However, it’s much more than just a simple cut. It’s a technique that requires precision, the right tools, and a keen understanding of wood behavior.

Why Resaw Wood?

There are several compelling reasons why I, and many other woodworkers, choose to resaw:

Maximize Lumber Yield: Resawing allows you to get more usable material from a single board, effectively doubling your lumber supply. This is particularly valuable when working with expensive or rare hardwoods.
Create Thin Stock: Many woodworking projects, such as drawer sides, box making, and inlay work, require thin stock. Resawing is the most efficient way to produce consistent thin boards.
Reveal Grain Patterns: Resawing can expose beautiful grain patterns hidden within a thicker board. This is especially true for figured woods like curly maple or quilted maple. By resawing and bookmatching the resulting pieces, you can create stunning visual effects.
Control Wood Movement: Thin stock is less prone to warping and cupping than thick stock. Resawing can help you create more stable components for your projects.
Cost Savings: Buying thicker stock and resawing it yourself can often be more economical than purchasing thin stock, especially for specialty woods.

Tools of the Trade: Choosing the Right Saw

The most important tool for resawing is, of course, the saw. While various saw types can be used, some are better suited for the task than others. Here’s a breakdown:

Bandsaws: The Resawing Champion

In my experience, the bandsaw is the ideal tool for resawing. Its vertical blade allows for deep cuts, and its continuous cutting action provides a smooth, efficient cut.

Bandsaw Size and Power: A bandsaw with a throat capacity of at least 6 inches is recommended for resawing. I personally use a 14-inch bandsaw with a riser block, which increases the cutting capacity to 12 inches. Horsepower is also crucial; a 1-horsepower motor is generally sufficient for most resawing tasks, but a larger motor (1.5-2 HP) will handle thicker, harder woods more easily.
Bandsaw Blades: The blade is the heart of the resawing operation. A wide blade (3/8 inch to 3/4 inch) with a low tooth count (3-6 TPI – teeth per inch) is ideal for resawing. The wider blade provides greater stability and resists flexing, while the low tooth count allows for efficient chip removal. I prefer blades made from high-speed steel (HSS) or bimetal for their durability and longevity.
Blade Tension: Proper blade tension is critical for accurate resawing. Insufficient tension will cause the blade to wander, resulting in a curved cut. Over-tensioning can damage the blade and the bandsaw. Refer to your bandsaw’s manual for the recommended tension settings. I use a blade tension gauge to ensure consistent tension.
Bandsaw Setup: Before resawing, ensure your bandsaw is properly tuned. This includes checking the blade alignment, adjusting the blade guides, and ensuring the table is square to the blade. A properly tuned bandsaw will produce cleaner, more accurate cuts.

Table Saws: A Viable Alternative (With Caveats)

While not as ideal as a bandsaw, a table saw can be used for resawing, particularly for thinner boards. However, there are limitations to consider.

Table Saw Height: The maximum resaw height on a table saw is limited by the blade diameter. A 10-inch table saw can typically resaw boards up to 3 inches thick, while a 12-inch table saw can handle boards up to 4 inches thick.
Resaw Fence: A tall resaw fence is essential for safe and accurate resawing on a table saw. This fence provides support and prevents the board from tipping over during the cut. You can purchase a commercially made resaw fence or build your own.
Multiple Passes: Resawing on a table saw typically requires multiple passes. You’ll need to flip the board over and make a second pass to complete the cut. This can be time-consuming and requires careful alignment to ensure the two cuts meet accurately.
Safety Considerations: Resawing on a table saw can be dangerous due to the potential for kickback. Always use a featherboard to keep the board pressed against the fence and wear appropriate safety gear, including safety glasses and hearing protection.

Hand Saws: The Traditional Approach

For those who appreciate the traditional methods of woodworking, resawing can be done with a hand saw. This requires skill, patience, and a specialized saw.

Resaw Saw: A resaw saw is a long, thin saw with a low tooth count (typically 4-5 TPI). It’s designed for cutting along the grain of the wood.
Sawing Technique: Resawing with a hand saw requires a steady hand and a consistent sawing motion. Use the full length of the blade and avoid forcing the saw. It’s helpful to use a marking gauge to create a reference line on the edge of the board.
Jigs and Fixtures: To improve accuracy, you can use jigs and fixtures to guide the saw. A simple resaw guide can be made from a piece of wood with a groove that fits the saw blade.

Preparing for the Cut: Wood Selection and Setup

Before you start resawing, it’s essential to select the right wood and prepare it properly.

Wood Selection

Wood Type: The type of wood you choose will affect the ease of resawing. Softwoods like pine and cedar are generally easier to resaw than hardwoods like oak and maple. Figured woods, such as curly maple or quilted maple, can be more challenging to resaw due to their irregular grain patterns.
Moisture Content: The moisture content of the wood is also important. Wood that is too wet can be difficult to resaw and may warp or cup after being cut. Kiln-dried wood with a moisture content of 6-8% is ideal for resawing. I always use a moisture meter to check the moisture content of the wood before resawing.
Grain Orientation: Pay attention to the grain orientation of the wood. Resawing along the grain is generally easier than resawing across the grain.

Setting Up Your Bandsaw for Resawing

Blade Selection: As mentioned earlier, a wide blade with a low tooth count is ideal for resawing. I typically use a 3/4-inch blade with 3 TPI for resawing hardwoods and a 1/2-inch blade with 4 TPI for resawing softwoods.
Blade Guides: Adjust the blade guides so they are close to the blade but not touching it. The blade guides provide support and prevent the blade from flexing.
Resaw Fence: A tall resaw fence is essential for accurate resawing. You can purchase a commercially made resaw fence or build your own. The fence should be tall enough to support the board throughout the cut.
Featherboards: Featherboards are used to keep the board pressed against the fence and the table. This helps to prevent the board from wandering and ensures a consistent cut. I use featherboards on both the infeed and outfeed sides of the blade.
Dust Collection: Resawing produces a lot of sawdust, so it’s important to have a good dust collection system in place. I connect my bandsaw to a dust collector with a 4-inch hose.

The Resawing Process: Step-by-Step Guide

Now that you have your tools and materials ready, let’s walk through the resawing process step-by-step.

Step 1: Marking the Cut Line

Use a marking gauge to create a reference line on the edge of the board. This line will guide you as you resaw. I prefer to use a wheel marking gauge, as it creates a cleaner, more accurate line than a traditional marking gauge.

Step 2: Setting the Fence

Adjust the resaw fence so that the blade is aligned with the marked cut line. Use a ruler or a combination square to ensure the fence is parallel to the blade.

Step 3: Feeding the Board

Start the bandsaw and slowly feed the board into the blade, keeping it pressed against the fence and the table. Use a push stick to keep your hands away from the blade.

Step 4: Maintaining a Consistent Feed Rate

Maintain a consistent feed rate throughout the cut. Feeding the board too quickly can cause the blade to wander, while feeding it too slowly can cause the blade to overheat. I find that a slow, steady feed rate produces the best results.

Step 5: Completing the Cut

Once you have resawed the board, turn off the bandsaw and wait for the blade to stop moving before removing the board.

Step 6: Repeat as Necessary

If you need to resaw the board into multiple pieces, repeat the process, adjusting the fence as needed.

Troubleshooting Resawing Problems

Even with the best preparation, problems can arise during the resawing process. Here are some common issues and how to address them:

Blade Wander: Blade wander is a common problem when resawing. It can be caused by a dull blade, insufficient blade tension, or improper blade alignment. To fix blade wander, try replacing the blade, increasing the blade tension, or adjusting the blade guides.
Curved Cut: A curved cut can be caused by blade wander or by feeding the board unevenly. To fix a curved cut, try using a featherboard to keep the board pressed against the fence and the table.
Burning: Burning can be caused by feeding the board too slowly or by using a dull blade. To fix burning, try increasing the feed rate or replacing the blade.
Rough Surface: A rough surface can be caused by using a blade with too many teeth or by feeding the board too quickly. To fix a rough surface, try using a blade with fewer teeth or decreasing the feed rate.

Advanced Resawing Techniques

Once you’ve mastered the basics of resawing, you can explore some advanced techniques to further enhance your woodworking skills.

Resawing Veneer

Resawing veneer requires a high degree of precision and a very sharp blade. I recommend using a thin-kerf blade with a high tooth count (14-18 TPI) for resawing veneer. You’ll also need a very stable fence and a method for supporting the veneer as it’s being cut. One technique is to sandwich the veneer between two pieces of MDF or plywood.

Resawing Curved Pieces

Resawing curved pieces can be challenging, but it’s possible with the right tools and techniques. You’ll need a bandsaw with a narrow blade and a flexible fence. You can also create a custom jig to support the curved piece as it’s being cut.

Bookmatching

Bookmatching is a technique where you resaw a board and then open up the two resulting pieces like a book, revealing a symmetrical grain pattern. This technique is often used for creating stunning visual effects in furniture and other woodworking projects.

Safety First: Protecting Yourself

Resawing can be a dangerous operation if proper safety precautions are not followed. Here are some important safety tips:

Wear Safety Glasses: Always wear safety glasses to protect your eyes from flying sawdust and wood chips.
Wear Hearing Protection: Resawing can be loud, so it’s important to wear hearing protection to prevent hearing damage.
Use a Push Stick: Always use a push stick to keep your hands away from the blade.
Keep the Work Area Clean: Keep the work area clean and free of clutter to prevent accidents.
Never Reach Over the Blade: Never reach over the blade while the saw is running.
Disconnect Power Before Adjusting: Always disconnect the power to the saw before making any adjustments or changing the blade.
Get Training: If you are new to resawing, get proper training from an experienced woodworker.

Case Study: Resawing Walnut for a Coffee Table

I recently completed a project that involved resawing walnut to build a coffee table. I started with a 2-inch thick walnut slab that I wanted to resaw into two 3/4-inch thick pieces for the tabletop.

Wood Preparation: I first checked the moisture content of the walnut slab, which was around 7%. I then flattened one face of the slab using my jointer and planer.
Bandsaw Setup: I installed a 3/4-inch wide blade with 3 TPI on my bandsaw and adjusted the blade guides. I also set up my resaw fence and featherboards.
Resawing Process: I carefully fed the walnut slab into the bandsaw, keeping it pressed against the fence and the table. I maintained a slow, steady feed rate throughout the cut.
Results: The resawing process went smoothly, and I ended up with two beautiful 3/4-inch thick walnut slabs. I then joined the two slabs together to create the coffee table tabletop.

This project demonstrated the value of resawing in creating custom lumber for woodworking projects.

The Economics of Resawing

Resawing can also be a cost-effective way to obtain lumber for your projects. Consider this scenario:

Purchasing Lumber: You need 10 board feet of 1/2-inch thick cherry lumber for a project. The cost of 1/2-inch cherry lumber is $10 per board foot, so the total cost would be $100.
Resawing Lumber: You purchase 5 board feet of 1-inch thick cherry lumber for $8 per board foot, for a total cost of $40. You then resaw the 1-inch lumber into 1/2-inch lumber, effectively doubling your yield.

In this scenario, resawing saves you $60 on lumber costs. Of course, you’ll need to factor in the cost of the bandsaw blade and the time spent resawing, but in many cases, resawing can be a more economical option.

Environmental Considerations

Resawing can also be an environmentally responsible way to use lumber. By maximizing the yield from each board, you can reduce the amount of wood that is wasted. This can help to conserve forest resources and reduce the environmental impact of woodworking.

Alternative to Resawing

While resawing is a great technique, there are also alternative methods for obtaining thin stock.

Buying Thin Stock: The most straightforward option is to simply buy thin stock from a lumber supplier. This can be a convenient option, but it may be more expensive than resawing your own lumber.
Using a Planer: A planer can be used to reduce the thickness of a board, but it’s not as efficient as resawing for creating thin stock. Planing also produces a lot of waste.
Using a Drum Sander: A drum sander can be used to sand a board to a specific thickness. This is a good option for creating very thin stock, but it can be time-consuming.

Maintaining Your Bandsaw for Optimal Resawing Performance

A well-maintained bandsaw is essential for accurate and efficient resawing. Here are some tips for maintaining your bandsaw:

Clean the Bandsaw Regularly: Remove sawdust and debris from the bandsaw after each use.
Lubricate Moving Parts: Lubricate the moving parts of the bandsaw regularly to prevent wear and tear.
Check Blade Tension: Check the blade tension regularly and adjust as needed.
Sharpen or Replace Blades: Sharpen or replace blades when they become dull.
Inspect Tires: Inspect the tires on the bandsaw wheels regularly and replace them when they become worn.
Align the Blade Guides: Align the blade guides regularly to ensure they are properly supporting the blade.

The Future of Resawing

Resawing is a technique that has been used for centuries, and it will continue to be an important part of woodworking in the future. With the development of new technologies, such as CNC bandsaws and advanced blade materials, resawing will become even more precise and efficient.

Conclusion

Resawing is a valuable skill for any woodworker. It allows you to maximize your lumber yield, create thin stock, reveal grain patterns, and control wood movement. While it requires the right tools, setup, and technique, the rewards are well worth the effort. By following the steps outlined in this guide, you can master the art of resawing and unlock the full potential of your woodworking projects. So grab your bandsaw, choose your wood, and get ready to create some perfect boards.