Should I Cut Drywall with a Table Saw?

Drywall can ruin a table saw.

Table saws allow the user to make long straight cuts in large sheets of wood. With a “fence,” that guides the wood panel; the user can slide the sheet smoothly along while the table saw does all the hard work. Drywall panels are very large and unwieldy, the smallest standard size being 4 feet in width and 8 feet long. A sheet of plywood of the same size would certainly benefit from the use of a table saw for cuting. However, there are better ways to cut a drywall panel.

• Drywall panels feature compressed gypsum particles that have a tendency to crumble when cut. Any power saw, including a table saw, will create clouds of drywall dust if used to cut the panels. The dust can clog the table saw motor and dull the blade of the saw.
• The nicest thing about drywall panels is that they break along a weak point. The best way to cut a panel, when you’re hanging drywall, is with a utility knife. You don’t even have to cut all the way through the panel; just score the panel on the front, “paper faced,” side, and then tap the backside of the panel and it will “break” along the scored line. 
• A drywall framing square is essential for making straight cuts. After measuring the panel, place the top of the square, which features a “T” shape, on the top edge of the drywall. The long vertical part of the square will extend downward, along the face of the panel.
• You can measure and cut out switch and outlet boxes, after the drywall's in place, with a utility knife, but there’s a much quicker way. A drywall zip-type router is similar to a hand drill, but with a long cutting bit.
  
  After poking the bit through the drywall panel and into the center of the outlet box beneath, turn on the tool. The bit spins, and you can guide it by sliding it to inner edge of the outlet box and following the inside perimeter all the way around. The zip-type tool keeps you from over cutting the drywall.

What Will I Need to Know to Repair My Ceiling Drywall?

Make ceiling drywall repairs promptly.

While your drywall ceiling appears smooth, it’s composed of large pressed gypsum panels, attached to the ceiling joists. Gypsum is relatively lightweight, making installation simple, but it is prone to cracking under pressure and crumbling upon impact. Water, from a roof leak may also damage the drywall panel. You’ll use the same tools to repair the damage that the drywall contractor used to initially install the ceiling.

 

Tools and Supplies

 

Drywall repair tools fall into two categories: mud application tools and supplemental tools.

To apply wet joint compound, you’ll use a small drywall-taping knife, or a putty knife, for restricted spaces. Mud shaping tools include wide drywall taping knives and trowels, used to feather out the wet mud along the ceiling. Inside corner-taping tools form a crisp corner between the ceiling and the wall.

Drywall sanding pads smooth away rough bits of dried joint compound and a utility knife is recommended for cutting drywall panels and drywall tape. If you’re making large repairs, a stud finder, a measuring tape and drywall screw gun are essential.

 

Materials

Most drywall repairs require only premixed joint compound, or “mud,” and drywall tape. If you’re replacing a damaged section of ceiling drywall, you’ll also need a new drywall panel.

Drywall tape comes in a thin paper roll or in fiberglass mesh. Pros use paper tape, but fiberglass mesh is more user-friendly.

 

Small Repairs

 

Hairline cracks require the application of wet joint compound, smoothed into the crack with a 6-inch taping knife, before sanding and painting the ceiling. Larger cracks require the application of drywall tape to help secure the joint compound in the crack.

 

Large Repairs

Broken out sections of drywall or large water stains may require replacing a section of drywall with a new panel. This is a major repair, and you’ll need to locate the ceiling joists, cut out the damaged section with a utility knife and then cut a corresponding replacement panel from new drywall.

You’ll need a drywall screwgun to attach the new section to the ceiling joists and then you’ll apply wet joint compound with a 6-inch drywall taping knife, seal the seams with drywall tape, and use a wider, 10-inch taping knife to feather out the wet compound.

 

Additional Supplies

When repairing ceiling drywall, wear splatter-proof eye protection and climb only on a sturdy ladder or scaffolding. Cover the floor with a non-slip drop cloth before you begin.