# Master Workshop Cutting Plan: 4' × 8' Sheet (35" + 35" + Leftover) ## Precision Cut Breakdown for 1/4" Baltic Birch Plywood into All 12 Dollhouse Panels > [!IMPORTANT] > **Summary Verdict**: Having your **4' × 8' sheet (48" × 96")** cut at **35 inches, then another 35 inches, and the leftover (~25.75" to 26")** was an **ideal strategy**! > 1. **100% Component Yield**: All 12 primary dollhouse panels (Floors, Facade, Side Gables, Partitions, and Roof Slopes) fit with zero compromises and comfortable safety margins. > 2. **Natural Grain Alignment**: Veneer grain runs horizontally across the facade and roof, side-to-side across room floors, and vertically up the gable walls. > 3. **Generous Offcut Scrap**: You have a massive **~25.75" × 15-3/8" bonus panel** left over—more than enough wood to build the **1:12 scale outdoor dog house**, staircase stringers, fireplace hearth, and test routing jigs! --- ## 1. Sheet Dimensions & Component Allocation ``` +==================================================================================================+ | ORIGINAL 4' x 8' PLYWOOD SHEET (48.00" WIDE x 96.00" LONG x 1/4" THICK) | +==================================================================================================+ | PIECE 1: 35.00" Long × 48.00" Wide | | ├── E1 Front Roof Slope: 32.00" × 12.04" (12-1/16") | | ├── E2 Rear Roof Slope: 32.00" × 12.04" (12-1/16") | | ├── C1 Front Facade Wall: 32.00" × 16.50" (16-1/2") | | └── Scrap Strip: 35.00" × ~7-1/8" (Available for trim & moldings) | +--------------------------------------------------------------------------------------------------+ | PIECE 2: 35.00" Long × 48.00" Wide | | ├── A1 Base Floor Deck: 32.00" × 12.00" (12") | | ├── A2 Second Floor Deck: 32.00" × 12.00" (12") | | ├── A3 Attic Floor Deck: 32.00" × 12.00" (12") | | ├── D1-A 1st Fl Partition: 12.00" × 8.25" (8-1/4") | | ├── D1-B 1st Fl Partition: 12.00" × 8.25" (8-1/4") | | └── Scrap Strips: 35.00" × ~3-1/4" + 10-3/4" × 8-1/4" (For stairs/furniture) | +--------------------------------------------------------------------------------------------------+ | PIECE 3 (LEFTOVER): ~25.75" to 26.00" Long × 48.00" Wide | | ├── B1 Left Exterior Gable: 24.90" (24-7/8") × 12.00" (12") | | ├── B2 Right Exterior Gable: 24.90" (24-7/8") × 12.00" (12") | | ├── D2-A 2nd Fl Partition: 12.00" × 8.25" (8-1/4") | | ├── D2-B 2nd Fl Partition: 12.00" × 8.25" (8-1/4") | | └── BONUS MASTER SHEET: ~25.75" × ~15-3/8" (2.75+ sq ft for Dog House, Hearth & Jigs!) | +==================================================================================================+ ``` --- ## 2. Sheet-by-Step Step-by-Step Cutting Guide Assumes standard **1/8" (0.125") saw blade kerf**. ### Sheet 1: 35.00" Long × 48.00" Wide *Target: Roof Slopes (`E1`, `E2`) & Front Facade (`C1`)* ``` |<------------------------- 48.00" Wide ------------------------->| --- +----------------+----------------+-------------------+----------+ ^ | | | | | | | | | | | 35.0" | E1: ROOF | E2: ROOF | C1: FRONT FACADE | OFFCUT | Long | (32" x 12.04")| (32" x 12.04")| (32" x 16.50") | STRIP | | | | | | (~7" W) | v | | | | | --- +----------------+----------------+-------------------+----------+ |<- 12-1/16" ->| |<- 12-1/16" ->| |<--- 16-1/2" ---->| ``` 1. **Rip 1 (Part E1)**: Set rip fence to **12-1/16" (12.04")**. Run the 35" length through to produce a **35.00" × 12-1/16"** strip. - Cross-cut stop block at **32.00" (32")**. Trim off 3.00" end to yield **`E1` (32.00" × 12-1/16")** (flush with carcass gables). 2. **Rip 2 (Part E2)**: Keep rip fence at **12-1/16" (12.04")**. Rip the second strip. - Cross-cut stop block at **32.00" (32")** to yield **`E2` (32.00" × 12-1/16")**. 3. **Rip 3 (Part C1)**: Set rip fence to **16-1/2" (16.50")**. Rip strip from the remaining stock. - Cross-cut stop block at **32.00" (32")** to yield **`C1` (32.00" × 16-1/2")**. 4. **Leftover Offcut**: You have a clean **35.00" × ~7-1/8"** strip remaining for moldings and trim! --- ### Sheet 2: 35.00" Long × 48.00" Wide *Target: Three Floor Decks (`A1`, `A2`, `A3`) & First Floor Partitions (`D1-A`, `D1-B`)* ``` |<------------------------- 48.00" Wide ------------------------->| --- +----------------+----------------+----------------+---------------+ ^ | | | | D1-A (12x8.25)| | | A1: BASE DECK | A2: 2ND FLOOR | A3: ATTIC |---------------+ 35.0" | (32" x 12") | (32" x 12") | (32" x 12") | D1-B (12x8.25)| Long | | | |---------------+ | | | | | OFFCUT (11x8) | v | | | |---------------+ --- +----------------+----------------+----------------+---------------+ |<---- 12" ---->||<---- 12" ---->||<---- 12" ---->||<-- 11-5/8" -->| ``` 1. **Rips 1, 2, and 3 (Parts A1, A2, A3)**: Set rip fence to **12.00" (12")**. - Make three successive passes to produce three identical **35.00" × 12.00"** boards. - Set cross-cut stop at **32.00" (32")**. Trim each board to yield **`A1`, `A2`, and `A3` (32.00" × 12.00")**. - *(Keep the three 2-7/8" × 12" end blocks for routing test scraps!)* 2. **Rip 4 (Partitions D1-A & D1-B)**: The remaining piece from Sheet 2 is **35.00" × ~11-5/8"**. - Set rip fence to **8-1/4" (8.25")** and rip down the length. - Set cross-cut stop to **12.00" (12")**: - Cut 1: yields **`D1-A` (12.00" × 8-1/4")**. - Cut 2: yields **`D1-B` (12.00" × 8-1/4")**. - Length used: $12.00" + 0.125" + 12.00" = 24.125"$. Leaves a **10-3/4" × 8-1/4"** scrap block! --- ### Sheet 3 (Leftover): ~25.75" to 26.00" Long × 48.00" Wide *Target: Two Side Gables (`B1`, `B2`), Second Floor Partitions (`D2-A`, `D2-B`), & Bonus Stock* ``` |<------------------------- 48.00" Wide ------------------------->| --- +----------------+----------------+----------------+---------------+ ^ | | | D2-A (12x8.25) | | | | B1: L GABLE | B2: R GABLE |----------------| BONUS SHEET | ~25.75"| (24-7/8"x12") | (24-7/8"x12") | D2-B (12x8.25) | FOR DOGHOUSE | Long | | |----------------| & STAIRS | | | | | SCRAP (1.6"x8")| (~25.75"x15") | v | | | | | --- +----------------+----------------+----------------+---------------+ |<---- 12" ---->||<---- 12" ---->||<--- 8-1/4" --->|<-- ~15-3/8" ->| ``` 1. **Rips 1 and 2 (Gable Walls B1 & B2)**: Set rip fence to **12.00" (12")**. - Cut two strips of **~25.75" × 12.00"**. - Set cross-cut stop block at **24.90" (24-7/8")**. Trim each piece to exact height to yield **`B1` and `B2` (24-7/8" H × 12" W)**. 2. **Rip 3 (Partitions D2-A & D2-B)**: Set rip fence to **8-1/4" (8.25")**. - Rip a **~25.75" × 8-1/4"** strip. - Set cross-cut stop at **12.00" (12")**: - Cut 1: yields **`D2-A` (12.00" × 8-1/4")**. - Cut 2: yields **`D2-B` (12.00" × 8-1/4")**. 3. **The Bonus Stock**: You are left with a massive solid piece of 1/4" Baltic Birch measuring approximately **25-3/4" × 15-3/8" (over 2.75 square feet)**! --- ## 3. Bonus Wood Utilization: Dog House & Accessories The remaining wood from Sheet 3 and offcut strips provides more than enough material for your other miniature projects: 1. **1:12 Scale Outdoor Dog House**: - The master plans for the dog house require an area of approximately **90 sq inches**. - Your Sheet 3 bonus panel has **395+ sq inches**—you can build the entire dog house (deck, walls, roof, porch) directly from this leftover piece with room to spare! 2. **Foyer Staircase (12 Steps & Stringers)**: - Uses three 2" × 6" offcut blocks from Sheet 2. 3. **Foyer Brick Fireplace Hearth**: - Uses small 5" × 1-1/2" scrap blocks from Sheet 1. 4. **Dado Depth Router Calibration Jigs**: - The three 2-7/8" × 12" end-cut blocks from Sheet 2 are perfect for dialing in your table saw or router to exact **1/8" (0.125") depth** before touching your final floor decks. --- ## 4. Master Fence Settings Summary (Ready for the Shop) | Rip Pass # | Sheet # | Rip Fence Setting | Target Components Cut From Strip | Cross-Cut Stop Setting | | :---: | :---: | :---: | :--- | :---: | | **1** | **Sheet 1** | **12-1/16" (12.04")** | Part `E1` (Front Roof Slope) | **32.00" (32")** | | **2** | **Sheet 1** | **12-1/16" (12.04")** | Part `E2` (Rear Roof Slope) | **32.00" (32")** | | **3** | **Sheet 1** | **16-1/2" (16.50")** | Part `C1` (Front Facade Wall) | **32.00" (32")** | | **4** | **Sheet 2** | **12.00" (12")** | Part `A1` (Base Floor Deck) | **32.00" (32")** | | **5** | **Sheet 2** | **12.00" (12")** | Part `A2` (Second Floor Deck) | **32.00" (32")** | | **6** | **Sheet 2** | **12.00" (12")** | Part `A3` (Attic Floor Deck) | **32.00" (32")** | | **7** | **Sheet 2** | **8-1/4" (8.25")** | Parts `D1-A` & `D1-B` (1st Fl Partitions) | **12.00" (12")** (Cut 2x) | | **8** | **Sheet 3** | **12.00" (12")** | Part `B1` (Left Exterior Gable) | **24-7/8" (24.90")** | | **9** | **Sheet 3** | **12.00" (12")** | Part `B2` (Right Exterior Gable) | **24-7/8" (24.90")** | | **10**| **Sheet 3** | **8-1/4" (8.25")** | Parts `D2-A` & `D2-B` (2nd Fl Partitions) | **12.00" (12")** (Cut 2x) |