When it comes to choosing between a worm drive and an inline circular saw, there are a few key factors to consider. The main differences come down to power, balance, and blade orientation. Let’s take a closer look at how these saws compare.
Page Contents
- 1 What is a worm drive saw?
- 2 What is an inline circular saw?
- 3 Power and Torque
- 4 Balance and Control
- 5 Maintenance
- 6 Common Uses
- 7 Recommendation
- 8 Top Brands
- 9 Factors to Consider When Choosing
- 10 Safety Tips
- 11 Current Circular Saw Costs
- 12 Cordless Circular Saws
- 13 Circular Saw Blade Selection
- 14 Other Comparable Saws
- 15 Circular Saw Usage Tips
- 16 Conclusion
What is a worm drive saw?
A worm drive circular saw has the motor oriented perpendicular to the blade. The motor connects to the blade via a gear reduction system that looks like a worm gear, hence the name. This gearing allows the motor to provide more torque and power to the blade.
Some key features of worm drive saws:
- Motor is positioned rear of the blade for better balance
- Provides more torque and cutting power
- Blade is on the left side (for right-handed users)
What is an inline circular saw?
An inline circular saw has the motor positioned inline with the blade, directly driving it. There is no gear reduction system. Inline saws tend to be more compact and lightweight than worm drives.
Some key features of inline saws:
- Motor is positioned inline with blade
- Tend to be lighter weight and more compact
- Blade is on the right side (for right-handed users)
Power and Torque
One of the biggest differences between worm drive and inline circular saws is the power and torque they can provide. The gearing in a worm drive allows it to generate much higher torque than a direct drive inline saw. This makes worm drives better suited for cutting through dense, thick material.
For example, a typical 7-1/4″ worm drive saw can generate around 5-6 HP of power. Comparable inline saws in the same blade size class often top out around 2-3 HP.
The added torque is essential when making long cuts or rips in hardwoods, composite materials, or pressure treated lumber. Inline saws are prone to bogging down or binding up in these tougher tasks.
Balance and Control
Inline circular saws tend to be lighter than worm drives, but that weight savings comes at the expense of balance. With the blade on the right side, inline saws feel unbalanced for a right-handed user. The awkward balance can make them more difficult to control.
Worm drive saws, with their weight distributed between the motor and gearbox behind the blade, have much better balance. This makes them easier to control, especially when making long rip cuts. The left-side blade orientation also feels natural for right-handed users.
Maintenance
The gearing in a worm drive saw does require more maintenance than a direct drive inline saw. The gears need periodic lubrication and eventually may need replacing after years of heavy use.
Inline saws have fewer moving parts so there is less to maintain. But the tradeoff is lower power and torque.
Common Uses
Here is a general overview of what each type of circular saw is best suited for:
| Worm Drive Saws | Inline Saws |
|---|---|
| Cutting thick hardwoods | Cutting thin wood and plywood |
| Ripping long cuts in lumber | Quick cross cuts and angled cuts |
| Heavy construction work | Trim carpentry |
| Cutting masonry and metals with specialty blades | Portability and ease of overhead cutting |
Recommendation
For most general residential construction work where you need to cut lots of lumber and wood studs, a worm drive saw is the better choice. The higher torque and power will help slice through dense materials with less binding or slow down. The rear motor position also provides excellent balance and control for long straight cuts.
An inline saw is a fine option for lighter duty work, especially if you value portability. The lighter weight makes it easier to maneuver for quick cutting jobs. But for consistent heavy-duty use, a worm drive saw is the preferred choice.
Top Brands
Some of the top brands for worm drive and inline circular saws include:
Worm Drive Saws
- Skilsaw – The original worm drive circular saw brand. Makes a variety of models.
- Makita – Known for powerful worm drive saws with magnesium components.
- DeWalt – Offers both corded and cordless worm drive saws.
Inline Circular Saws
- Makita – Wide range of compact inline saws.
- Milwaukee – Quality inline saws, includes cordless options.
- Rockwell – Affordable inline saw models, corded and cordless.
Factors to Consider When Choosing
Here are some key factors to keep in mind when choosing between worm drive and inline circular saws:
- Power – Worm drive saws provide more torque and cutting power.
- Balance – Worm drives feel more balanced and easier to control.
- Weight – Inline saws tend to be several pounds lighter.
- Maintenance – Worm drive gearing needs more maintenance.
- Blade orientation – Inline blades are right-side, worm drives are left.
- Cost – Quality worm drives tend to cost more than inline saws.
Consider what types of projects you’ll be using the saw for and how often you’ll need the extra power of a worm drive model. This will help determine if the higher cost is justified.
Safety Tips
Circular saws are powerful cutting tools that need proper safety precautions. Here are some tips to use either type of circular saw safely:
- Read and understand the instruction manual before use.
- Always wear safety glasses or a face shield.
- Use hearing protection – circular saws are very loud.
- Don’t cut materials that cause excessive dust or fumes.
- Avoid awkward overhead cutting positions.
- Support long boards so they don’t pinch the blade when cut.
- Pay attention to the SawStop safety techonology that stops the blade on contact.
- Unplug saw when changing blades or making adjustments.
- Keep your fingers well away from the blade path!
Current Circular Saw Costs
Here is an overview of current price ranges for worm drive and inline circular saws:
| Circular Saw Type | Typical Cost Range |
|---|---|
| Worm drive saws | $130 – $400 |
| Inline saws | $100 – $200 |
These are general prices for corded circular saws from leading brands. Additional features like higher amp motors, magnesium housings, and electric brakes will raise costs. Cordless saws cost more than corded equivalents.
Cordless Circular Saws
Cordless circular saws provide untethered convenience but cannot match the raw power of corded models. But the gap is shrinking as battery technology improves. As of 2022, here is how cordless saws compare:
- Lower torque and cutting power than corded equivalents.
- Typically 40% less power than similar corded saws.
- Best for lighter duty cutting tasks.
- Runtime is limited by battery life.
- Higher initial purchase cost over corded saws.
Top cordless circular saw models can cost $400 or more just for the saw with two batteries. But they provide excellent freedom of movement and are adequate for lighter carpentry work in most cases.
Circular Saw Blade Selection
The type of circular saw blade you choose impacts cutting performance. Here are some blade considerations:
- Material – Carbide-tipped blades last the longest.
- Tooth count – More teeth cut slower but smoother.
- Gullet depth – Deeper gullets clear more material.
- Kerf width – Thinner kerf requires less power.
- Coating – Coatings reduce friction and corrosion.
- Diameter – Larger diameters cut deeper.
Match your blade selection to the thickness and type of material you plan to cut. Ask a knowledgeable salesperson for recommendations if unsure.
Other Comparable Saws
There are a few other saw types that compete closely with circular saws for cutting applications:
Miter Saws
- Excel at quick, accurate cross cuts at various angles.
- Limited cutting depth and width capacity.
- Chop saws are low cost miter saw options.
Table Saws
- Provide exceptional cutting accuracy.
- Powerful models for ripping thick stock.
- Less portable than handheld circular saws.
Reciprocating Saws
- Compact and very portable.
- Limited depth of cut and accuracy.
- Mainly used for demolition tasks.
For many construction jobs, a quality circular saw is the best all-around option for making both cross cuts and rips with good accuracy.
Circular Saw Usage Tips
Here are some helpful tips for making clean, accurate cuts with a circular saw:
- Use a sharp, quality blade designed for your cutting task.
- Ensure the saw’s base plate is parallel to the blade.
- Clamp a guide to the workpiece for straight rips.
- Support the work so the off-cut piece doesn’t pinch the blade.
- Let the blade reach full speed before starting cut.
- Move the saw smoothly through the cut without twisting.
- Cut finish-side up when possible to reduce splintering.
With practice and these tips, you can achieve expert-level cuts. Proper saw setup and technique makes a big difference.
Conclusion
When choosing between worm drive and inline circular saws, there are clear tradeoffs in power vs portability. Worm drive saws provide more torque for demanding cuts through dense materials. But inline saws are lighter and easier to use for quick tasks. Consider how you plan to use the saw and your budget to decide which type is the better fit.