Don Vandervort, Head Homeboy, has written more than 30 DIY home improvement books, been a segment host on HGTV, served as MSN.com's home improvement expert and written countless magazine articles.
You can make simple cross cuts in composite decking the same way you would cut any soft pine—a power circular saw will work fine. A power miter saw can provide very accurate, straight cuts, and a table saw with support extensions can make all types of cutting easier. Carbide tipped blades are suggested--the fewer teeth the better for smooth cuts. Don’t allow blades to get overly hot when cutting—this can cause cuts to be warped or wavy.
Ripping the composite board (cutting lengthwise) is trickier. Even the most experienced carpenters have found that when the power saw’s blade heats up, it creates slight waves along the cut line. Whenever possible try to avoid ripping composite decking and use full boards for your surface. If you do have to rip, put the rough, exposed cut side where flaws will be least noticeable.
If installing the decking around an existing structure, a simple router can be used to make curved cuts. Again, treat the material just like you would soft pine, but be sure to secure the board in place to help stabilize the cut.
A clean cut should not leave any loose material, but if you need to clean up an edge, do not use a sander. Sanders will mar the finish and in many cases void your warranty. A hand coping saw will work well to smooth finished edges if needed.
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