Guides

Plan the cut before you touch the saw

Cut lists, sheet counts, kerf, grain and cutting order, worked through with real projects. Every diagram and number comes from the same optimizer that runs in Plyplan.

96" 48" grain → Shelf34 3/8" × 11" Shelf34 3/8" × 11" Top / bottom11 1/4" × 34 1/2" Top / bottom11 1/4" × 34 1/2" Side72" × 11 1/4" Side72" × 11 1/4" Shelf34 3/8" × 11" Shelf34 3/8" × 11"
2500 mm 1250 mm grain → Shelf876 mm × 279 mm Shelf876 mm × 279 mm Top / bottom285 mm × 879 mm Top / bottom285 mm × 879 mm Side1830 mm × 285 mm Side1830 mm × 285 mm Shelf876 mm × 279 mm Shelf876 mm × 279 mm 879 mm × 75 mm

How to make a plywood cut list, step by step

From a sketch to a sheet layout, with a full bookcase as the worked example.

9 min read

96" 48" grain → 48" × 24"
2500 mm 1250 mm grain → 1250 mm × 625 mm

How many sheets of plywood do you need?

Why dividing by sheet area gives the wrong answer, with five projects measured.

6 min read

96" 48" grain → 96" × 12" 96" × 12" 96" × 12"
2500 mm 1250 mm grain → 2500 mm × 312.5 mm 2500 mm × 312.5 mm 2500 mm × 312.5 mm

Saw kerf explained: what it costs and how to allow for it

Why four equal strips do not come out of a sheet that divides evenly.

6 min read

96" 48" grain → 44" × 30" 44" × 30"
2500 mm 1250 mm grain → 1120 mm × 760 mm 1120 mm × 760 mm

Plywood grain direction: when it matters and what it costs

How to read a sheet, which parts to lock and when it costs an extra sheet.

6 min read

96" 48" grain → Front / back36" × 20" Front / back36" × 20" End16 1/2" × 20" End16 1/2" × 20" Lid37" × 19" Bottom34 1/2" × 16 1/2"
2500 mm 1250 mm grain → Front / back915 mm × 510 mm Front / back915 mm × 510 mm Lid939 mm × 484 mm Bottom879 mm × 424 mm

What order to cut plywood in

Breaking down a full sheet, then a numbered cut sequence for a real project.

7 min read

96" 48" grain → Side60" × 11 1/4" Side60" × 11 1/4" Top / bottom28 1/2" × 11 1/4" Top / bottom28 1/2" × 11 1/4" Fixed shelf28 1/2" × 11 1/4" Shelf28 3/8" × 11" Shelf28 3/8" × 11" Shelf28 3/8" × 11" Shelf28 3/8" × 11" 3" × 28 1/2"
2500 mm 1250 mm grain → Side1500 mm × 285 mm Top / bottom724 mm × 285 mm Side1500 mm × 285 mm Top / bottom724 mm × 285 mm Fixed shelf724 mm × 285 mm Shelf721 mm × 279 mm 724 mm × 75 mm Shelf721 mm × 279 mm Shelf721 mm × 279 mm Shelf721 mm × 279 mm

One-sheet plywood bookcase: full cut list and cutting plan

A full-height bookcase carcass from one sheet, with every part and cut.

5 min read