If you are an avid wine drinker, the chances are that you have a pile of corks lying around. Or you like collecting corks to make crafts out of them. Corks are a fun addition to woodwork projects, whether to line a table with corks or to decorate a wooden photo frame. However, the problem with cutting corks is that they are tough to cut and tend to crumble.
In this article, we will give you step by step guidelines on how to cut corks fast and clean, whether you are a DIYer looking for a fun new project or someone who cuts corks for a living.
Contents
How To Cut Corks –Step By Step Guide
The Easy Method
There are two ways to cut corks, depending on the quantity and frequency. If you are someone who wants to make something fun out of corks as a one time project, this is the method for you.
Step 1
Wear anti-cut heat resistant gloves. Take a steamer. Pour water into it. Put it on the stove and turn on the stove. In case a steamer is not available, take a large vessel and fill it with water. Place it on the stove and turn on the stove.
Step 2
Add the corks to the steamer or the large vessel. Depending on the vessel you are using, steam the corks or soak the corks in hot water for ten minutes.
Step 3
Take out the corks and lay them on the cloth. Wait till they are dry. However, the corks must not lose their heat.
Step 4
Take a cutting board. Using a serrated knife, cut through each cork in the shapes you want. Once they are cut, lay them back on the cloth and wait till they are completely dried and cooled off.
The Professional Method
Step 1
Wear personal protective gear: the anti-cut heat resistant gloves, earplugs, face mask, and clear eyewear. Take the plywood and, using the circular saw, cut 45-degree bevels on parallel sides of the plywood. Make sure that the bevels are along the same side that is the bevels match. The plywood should form a parallelogram with 45 degrees bevel angles. You can cut formica’s and rafters like this too.
Step 2
Using a tape measure, measure the length of the longest cork that you have in your collection. The length that you need to cut the plywood would be ¼ inch more than the measured value. So, if the length of the cork is 1.5 inches, we will need the plywood of 1.75 inches each. Using a marker and tape measure, mark the points on the plywood. We will need two such pieces of plywood. Using the saw, cut the two pieces of plywood.
Step 3
Using the superglue and accelerant, stick the two flat sides of the plywood together to form a ‘V.’ You need to stick together the beveled sides, such that when the pieces are put together, it looks like a miniature couch without legs. Spread the glue generously on one of the sides, which needs to stick together. On the other side, to be stuck together, apply the accelerant. Press the two pieces together. In about 10 seconds, the pieces should bond. Using a sander, smoothen the sides if required.
Step 4
Now, we will make the sideboards for the V-shaped piece. Take the ¼ inch plywood. Place the V-shaped plywood you just made on one corner of the ¼ inch plywood with the V facing the ply. Using the marker, mark the place the V ends. Cut off the piece with the saw such that the sideboard completely covers the V on one side.
Using the CA glue and accelerant. Stick the sideboard and the V together. Repeat the same process using a ¾ inch plywood to the other V-side. Cut another piece of the ¾ inch plywood and cut it to the same dimensions as the first ¾ inch. Place it on the already stuck ¾ inch, and using the glue and accelerant, stick it on top of it. Use the sander or file to smoothen any surfaces if required. Now the V-piece has two sideboards sticking to it, one of ¼ inch and the other of 2 pieces of ¾ inches on top of each other.
Step 5
Take a sheet of ¼ inch plywood, about 10 inches by 10 inches piece. This piece will be used as a resting board for the jig. Place the jig on one of the sides of the sheet such that it is at the center of the board. Pull back the piece by about ¼ inch. Place the jig on the sheet such that the V sort of stands on the sheet.
Step 6
Take the jig and using the band saw, cut a slice through the V such that it cuts through the ¼ inch sideboard completely, and goes through to the ¾ inch, touching the ¾ slightly. Widen the slice slightly. Now, using a hand saw, cut the ¼ inch play, mimicking the V shape, leaving behind some tolerance. This step is optional, but it will help in easy removal of the cork once it is cut. Sand off any surfaces if necessary. If needed, reinforce any sides and edges of the jig using the CA glue and accelerant.
Step 7
To cut the corks, place the cork in the V-shaped bed of the jig. Using the relief slice as a reference, cut the cork using the band saw. Stop when the saw reaches the ¾ inch plywood. Make sure that you push the jig into the saw slowly; else, the cork pieces can fly off.
The Easy Method
- A large vessel: The best vessel would be a steamer. However, if you do not have access to a steamer, any large vessel would work.
- Water: We will need water to add to the steamer. In the case of the large vessel, the water will be used to soak and soften the corks.
- A Stove: Any stove which holds the steamer or vessel in place can be used. We will be using it to heat the water.
- A Cutting Board: Any standard cutting board can be used. We will be using this as a base while cutting the corks.
- A Cloth: Use a thick water-absorbent cloth as it will be used to dry the corks
- A serrated knife: While any knife can be used, a serrated knife works best as it can cut through easily, similar to cutting bread.
- Personal protective gear: You will need anti-cut, heat resistant gloves. However, if you are sensitive to heat or steam, wear a face mask and protective eyewear.
For The Professional Method
- ½ inch plywood, ¼ inch plywood, ¾ inch plywood: the advantage of this jig is that this can be made using the scrap block of plywood you already have in the shop. Since it is a small-sized jig, you wouldn’t need to purchase extra plywood.
- Marker, tape measure, and speed square: Any standard marker, tape measure, and speed square can be used. Make sure that the marker works on wood.
- Thick CA glue and accelerant: The CA glue is also called as super glue. The accelerant dries up the glue in seconds, making the whole process simple, easy, and quick. While the same effect can be achieved using nails and screws, since the jig is going to be a small one using plywood, it is better to use glue. The nails or screws can chip off the small pieces of plywood.
- Compound saw with a bevel angle of 45 degrees, a band saw, and a hand saw: this can be a handheld saw or a circular saw—any saw which can accurately cut 45-degree bevels. The bandsaw will be used to cut the corks and the pieces of play in shape. The handsaw is optional for spots where cutting with the bandsaw would be difficult. A similar method is used to cut railway ties.
- Sander or file: this will be used to sand off or smoothen any sides if required.
- Personal protective gear: This includes anti-cut heat resistant gloves, protective clear lens eyewear.
FAQs
1. Why should I soak corks in hot water before cutting them?1.
Corks harden over time and can crumble if cut with a knife. Soaking it in hot water softens the corks enough to cut them evenly with clean cuts.
2. Can corks be cut using a hand saw?
Corks cut using a hand saw can crumble. Use an automatic saw to cut corks. If you want evenly cut corks, use a band saw with using a jig. Build the jig using the steps given in the article.
Final Thoughts
Whatever reason you need to cut corks, there is no denying that hacking it with a knife or saw will lead to uneven cuts, and a lot of the corks wasted in crumbles. We hope that this article has given you enough knowledge to cut corks quickly and easily, whether for a one-time project or something you need to do regularly.
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