While it is still relatively easy to cut holes out of a piece of wood (hole saw, step drill, etc.), it is a bit more complex for a rectangle. The advantage of straight cuts contrasts with the disadvantage of the geometric figure, which is not round. So that you can saw the rectangle in wood, I wrote the following article:
Table of Contents
Which saws can you use for sawing a rectangle in wood?
Well, in my opinion, there are two saws available here: the jigsaw and the plunge saw. With these two devices, it is possible to saw out a rectangle from a piece of wood and thus make an internal cut. With the plunge-cut saw, it is optimal if a guide rail is included.
You cannot do this with other saws. A normal circular saw, or hand saw always needs a connection from the outside. You cannot start in the middle of the workpiece.
The best example is cutting out the sink from the kitchen worktop. Again, it is best to use either the jigsaw or the plunge saw.
Personally, I prefer the jigsaw to the plunge saw, but that’s a matter of taste.
Related: Best Bandsaw for resawing
How to do it with a plunge-cut saw
A plunge-cut saw has the advantage over a conventional hand-held circular saw that it dips into the workpiece and therefore, the blade sits elevated over the guide rail.
Here you can see the difference between a classic circular saw and a plunge saw.
However, the big advantage of the plunge-cut saw is that the cut is exactly straight, which is not 100% the case with the jigsaw.
The small disadvantage of the plunge-cut saw compared to a jigsaw, however, lies in the fact that you cannot get into the corner with an internal cut.
You will therefore have to saw at all four corners. You can do this by hand or with a jigsaw. Plus, it’s not bad to re-drill the corners as well.
From my perspective, it is also essential that you use a good circular saw blade for this purpose. I can recommend an HM saw blade with a relatively large number of teeth suitable for wood and fits into your plunge-cut saw.
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How to do it with a jigsaw
Here I would like to show in practice how I do it when I have to saw out a rectangle out of wood:
Step 1 – drawing
First, you have to mark the rectangle that you want to saw out later. To do this, take a clearly visible pen and draw the rectangle in a clearly visible manner. It would help if you also used an angle to construct.
It would be best if you marked the rectangle neatly and clearly.
Step 2 – pre-drilling
With a jigsaw, you first have to drill a hole (inside the rectangle to be sawn) so that you can continue working with the jigsaw blade from there. This hole should be large enough to allow enough space for the saw blade.
I do that four times – one hole on each side – so that it’s easy for me.
Four holes are pre-drilled in the wood.
Step 3 – choose the saw blade
The right saw blade, in this case, is one for straight cuts in wood. In other words, one that has a certain width and is not easily distracted while sawing.
If necessary, there is also one for curvy cuts. Clamp it into the jigsaw.
When sawing, wear adequate protective clothing such as protective goggles, hearing protection, and the like.
You should use a saw blade for straight cuts (left) – if necessary, one can also be used for curved cuts (right).
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Step 4 – saw the rectangle out of the wood
Now guide the jigsaw into one of the drill holes and put the saw into operation. Hold it firmly and securely in your hand and drive along the marking into a corner of the rectangle.
Then stop and work in the next drill hole. Guide the saw back into the corner. You have to do this twice on each drill hole, once in one direction and then in the other.
Saw it from a hole in any corner …
… Then saw another hole in this corner.
Step 5 – post-processing
If you have done everything correctly, the remaining piece should now fall out and leave an incised rectangle. The more precisely and carefully you have worked, the more beautiful the cut edge should be.
If necessary, you can carefully rework this with a wooden file or a chisel.
This is what the result looks like – most of the time, there is still work to be done.
It is not difficult at all to saw a rectangle in wood. All you need is a suitable saw, a drill, and a good saw blade.