Cordless tools just keep getting better and better. And that
stalwart friend of remodelers, plumbers, and errant framers
everywhere — the reciprocating saw — is showing up
on job sites these days more and more often without a
cord.
If you haven't had the chance to try out these tools, do so.
They're expensive, but if you think about what it costs per
hour to roll out cords, or what it does to your attitude when
you have to crawl back and forth through the crawlspace to
untangle the cord or plug it back in, you might decide a
cordless recip saw is just what you need.
For this review, I looked at eight pro-duty saws. I used each
saw for a variety of light tasks, putting them all through
several charge and discharge cycles to condition the batteries
and get the feel of the tools. Then, to check power and
run-time under more rigorous conditions, I used each tool to
make as many cuts as the battery would allow through a 2x6
embedded with three sinkers. To check cutting speed, I timed
each saw through an 8-foot rip of 7/16-inch OSB.
For each task, the saws were fitted with a new Magna M90452
Progressive Tooth all-purpose blade. This is an excellent blade
for all-around use (see
"Tool Test: Recip
Blade Demolition Derby," 5/99), and it happens to be 0.050
inch thick, which seems to be a good compromise between the
standard 0.035-inch blades and the 0.062 demolition blades. At
this thickness, it provides the rigidity necessary for heavy
work without the high load associated with wide tooth
configurations.
Battery interchangeability is a consideration when buying
cordless tools, especially if you already own several tools of
any given voltage and brand. If you are an occasional recip
user, and already own some 14.4-volt DeWalt or Makita tools,
you might choose to buy one of their saws. But if a recip is a
primary tool for you, I would choose one of the higher-voltage
tools and keep a couple of batteries handy. The difference in
performance is worth it.
I've rated each saw on several subjective and objective
considerations, summarized in the chart below. While every one
of these saws is certainly suitable for professional use, some
clear favorites did emerge. Match your requirements against the
description to find the one that suits you best. Power and
run-time are important, but so are balance, controls, quality
of construction, and overall feel. Don't overlook the case, and
give some thought to what other tools run on the same battery.
If money were no object I'd buy the Bosch 1645, but with my
tool budget, I would more likely buy the Milwaukee 6515-21 or
the Porter-Cable 9837.
Bosch 1645
By far, this felt like the smoothest, most powerful saw of the
lot. With the flip of a switch, the 1645 offers a choice of
stroke length: The 3/4-inch stroke provides minimal vibration,
closer control of stroke depth, increased power, and precise
control on plunge cuts or thin materials; the 11/4-inch stroke
makes for fast cutting through soft materials, especially wood.
As a result, the saw handles exceedingly well at a variety of
tasks. The trigger switch is responsive throughout the speed
range; the quality of construction appears to be excellent; and
the weight, balance, and overall feel of the saw are
pleasing.
On the down side, I didn't like the placement of the pivot
point on the shoe, which was rarely positioned where I wanted
it to be relative to the work. Also, the battery release is a
little sticky, especially in cold weather. The tool-free blade
clamp on this saw was the only one of the bunch to give me any
trouble. It jammed once under heavy use, and the relatively
exposed design is such that I would be concerned about packing
it full of dirt or damaging it under rough conditions. However,
it holds well. I had no trouble with it on a roof demolition. A
conventional blade clamp is available as an optional accessory.
Despite these few relatively minor shortcomings, this is an
outstanding tool, and the only saw reviewed that is suitable
for heavier tasks.
DeWalt DW008K
If run-time is your primary consideration, look no further.
With over 40% more run-time than the Bosch, almost double the
run-time of most other saws, and plenty of power for most
tasks, this is one fierce recip. Vibration and noise approach
excessive levels, but I guess you don't get something for
nothing. The trigger switch works well, and the blade clamp is
among the easiest and most convenient. However, the dual-range
speed control and trigger lock are too stiff, as is the battery
release. Quality of construction seems fair, and weight and
balance of the tool seem to be a bit on the light side compared
to most. This model is also available with an AC/DC converter,
which is the same size as the battery pack. This allows
unlimited run-time without changing the balance of the tool
DeWalt DW938K and DW937K
Although it will get the job done, the DW938K has been
eclipsed by recent introductions. It is relatively light,
vibrates excessively, and is noisy enough that it feels a
little tedious to use. On the plus side, the run-time is above
average, the controls are first rate, and the blade clamp, like
that on the other DeWalt models, couldn't be easier to use. If
light weight and compatibility with existing tools are primary
concerns, this could still be a good buy. The DW937K is
basically the same saw as the 938K, except lower voltage.
Makita JR180DA and JR140DA
With the power you'd expect from an 18-volt tool, reasonable
noise levels, and minimal vibration, the JR180DA is comfortable
and agreeable to use. It feels solid, and the controls are
first rate, as is the overall quality. The trigger-switch
safety lock is configured such that the lock must be depressed
at each trigger use — an extra bit of safety that's easy
to get used to. The blade clamp is among the fastest, allowing
for effortless blade changes even at the fully retracted end of
the stroke. It also (usually) ejects the blade when the clamp
is released, making blade changes that much easier. The sliding
shoe works well, and the pivot point on the shoe is just right.
Externally accessible brush holders are another nice touch. The
limitations on this saw compared to the larger models are
stroke length, power, and run-time. If Makita comes out with a
24-volt model, it's going to be a serious contender. The Makita
JR140DA is basically the same saw as the JR180A, except lower
voltage.
Milwaukee 6515-21
My first impression of this saw was that it felt exactly like
a Milwaukee Sawzall. Not entirely trusting that intuition,
however, I got the AC Sawzall and used the tools side by side.
Yup, it's definitely a Sawzall — strong, well built, and
entirely likeable. The slower SPM speed, top of the line
low-speed trigger control, and plenty of power made it easy to
work with and the balance couldn't be much better. The saw is
noisier and vibrates more than most, though less than the
DeWalt saws.
The blade clamp is excellent, and the saw looks and acts like
it will take a beating. In fact, by the time we got done with
it, it looked like it had. Regarding the blade clamp, this
manufacturer had some trouble awhile back but seems to have
resolved it. To test this, I removed the shoe and bashed the
clamp into a concrete block with the saw running at full speed
(don't try this at home, folks). I then reinstalled the shoe,
inserted a blade, and it all worked just fine.
The metal case appears to be the sturdiest of the lot, and it
has plenty of room for spare blades. Besides the vibration, the
only drawbacks I found on this saw was the requirement for a
hex wrench when adjusting the shoe and a tendency for the
battery to fall off under extra-heavy use.
Porter-Cable 9837
Modeled on the Tiger Saw, the 19.2-volt “Tiger without a
Tail” is in a class by itself. If compact size or
accurate, stable cuts are a priority, this is the saw to
choose. Occupying a niche between the 18-volt and 24-volt saws,
it’s the shortest and heaviest saw of those reviewed.
This results in a decidedly front-heavy balance, which I found
pleasant in use. By far, this saw was the most stable through
the cut and the easiest to control. Vibration is noticeably
lower than in most of the others, which may be part of the
reason for this tool’s good-natured performance. Cutting
speed through nail-embedded 2x6 studs was better than most, and
it excelled at fast cutting through OSB as well.
The battery release is sticky, but otherwise the ergonomics
and controls are excellent. It’s difficult to change
blades in the fully retracted end of the stroke, so it would be
nice if the saw were redesigned either to stop the blade toward
the extended position or to make access to the blade clamp
easier. Like that of the Milwaukee saw, the 9837’s
adjustable shoe requires a hex key.
Dave
Crosby is an associate editor for The Journal of
Light Construction.