Cutting book board by hand can seem daunting, but with the right tools and techniques, you can achieve clean, precise cuts. As an avid bookbinder, I’ve tried multiple methods over the years. In this complete guide, as a professional board book printing manufacturer, I’ll share everything I’ve learned about how to cut binder’s board and bookboard by hand.
Why Cutting Book Board Is Tricky
Book board, also known as binder’s board or Davey board, is dense, durable cardboard used to create hard book covers. It comes in various weights and sizes. Heavier boards like 0.098″ are very difficult to cut through compared to lighter 0.059″ boards.
I’ve broken many blades trying to saw my way through thick book board. The key problem is that the board easily slips and shifts while you’re applying pressure. This leads to jagged edges, uneven corners, and potential injuries.
Proper hand cutting technique and the right tools are critical for getting clean Results.
Best Tools for Cutting Book Board
While power tools like table saws can slice through book board with ease, most bookbinders cut covers by hand. Here’s an overview of manual tools that produce the best results:
Metal Ruler
Look for an aluminum or steel ruler at least 12-18” long. Stainless steel offers maximum durability, with no risk of rust over time. Cork backing on the ruler prevents slipping.
Cutting Mat
Self-healing cutting mats provide an excellent surface for accurate cuts. The gridded measurements help with precision.
Utility Knife
A heavy-duty utility knife with frequent blade changes is ideal for book board. The thick, sturdy metal handles greater force without snapping.
Bench Hook
A bench hook braces your work and gives added leverage for tougher cuts. Easy DIY designs work fine.
Triangle Square Ruler
Ensuring precise 90-degree corners is essential for proper book construction. Get an adjustable triangle ruler for marking cuts.
How to Cut Book Board by Hand: Step-By-Step Guide
Follow these key steps to cut flawless book board pieces by hand:
Secure Your Workspace
Start by clearing an area to work in and covering the surface with a cutting mat. Secure your metal ruler and book board on the mat. Use a bench hook to hold everything firmly in position.
Mark Your Cuts
Use a triangle square ruler to ensure your book board corner is precisely 90 degrees. Measure and mark your desired cut lines on the board with a pencil. Mark the board on both sides to create a cutting guide.
Align and Anchor
Position your metal ruler flush along the marked cutting line. Anchor it in place with gentle but firm pressure. Keep hands safely clear of the blade line path.
Cut Slowly In Sections
Start each cut applying very light pressure, then increase pressure as you continue. Cut an inch or so, then lift and reposition the blade at the starting point to realign. Avoid cutting all the way through in one pass.
Frequently Change Blades
A sharp blade is essential every few cuts. Dull utility knife blades drag and tear book board rather than slicing it. Switch to fresh blades often for best control.
Check Accuracy
Periodically measure corner angles and cut width during the process. Fine tune as needed before finalizing cuts. Sand smooth any small imperfections for polished results.
Helpful Tips and Tricks
Follow these additional pointers to master how to cut binder’s board and bookboard yourself:
- Stand upright while cutting to utilize body weight and avoid hand strain. Use both hands for added stability.
- Cut stacks of lightweight boards first before moving to thicker, tougher boards. This preps your hands and technique.
- Try thinner 0.098” board if cutting a full 0.16” board proves overly difficult and tiring.
- Cut inch by inch rather than attempting long cuts all at once. Short strokes give better control and accuracy.
- Add painter’s tape beneath the ruler blade path to reduce tearing on board bottom edges.
- File problem edges using 200+ grit sandpaper to quickly straighten and smooth imperfect cuts.
Proper hand cutting technique takes patience and practice. Follow these book board cutting tips, upgrade your knife blades frequently, and keep your workspace secured. With time, you’ll be slicing through binder’s board with ease.
FAQs About Cutting Book Board
Here are answers to some frequently asked questions about cutting binder’s board and bookboard by hand:
Is a guillotine cutter better for cutting book board?
- Yes. An industrial guillotine cutter produces extremely straight, precise book board cuts in a fraction of the time. But the cost is quite high around $2,000+, putting industrial cutters out of reach for most hobbyist bookbinders.
What blade is best for cutting thick book board?
- Heavy-duty utility knife blades that are thick with a pronounced hook shape work best. The rigid steel and angled design provide added force and leverage when cutting through dense book board materials by hand. Replace often!
Can I cut binder’s board on a table saw?
- You can, but it’s a potential safety hazard for inexperienced users. A table saw with the proper blade and slow feed rate slices book board cleanly and neatly. But kickback risks mean beginners should avoid table saws for binder’s board projects.
Any alternatives for cutting book board perfectly straight?
- Beyond razor straight edge cuts freehand (very difficult!), bookbinding board shears produce precise cuts with smooth finished edges at 90 degree angles. Board shears leverage compound leverage, allowing effortless slicing through nearly any book board thickness.
I hope these insights and step-by-step advice give you the confidence to start neatly and accurately cutting book board and binder’s board yourself. Let me know if you have any other questions – I’m always happy to help!