Milwaukee Worm Drive Circular Saw

Owning a reliable and powerful circular saw is essential for both professional contractors and serious DIY enthusiasts. The Milwaukee 6477-20 Worm Drive Circular Saw quickly reveals itself as a contender for the ultimate cutting tool, boasting robust features and impressive performance. With its 7-1/4" blade and durable construction, this saw is designed to handle demanding cutting applications with ease.

Engineering and Build Quality

One of the first things I noticed about this saw is its substantial build quality. It's made with magnesium construction, which strikes a good balance between durability and weight. At 15 pounds, it's not the lightest saw out there, but the heft contributes to its stability during cuts. There's a reassuring solidity to it that suggests it can withstand the rigors of a busy job site.

The saw’s base plate is a composite material, which initially raised some concerns. Typically, metal is preferred for its ability to withstand wear and tear. However, the composite shoe on this model is reinforced with fiberglass and resists warping and bending quite well. It’s surprisingly durable, though only time and extensive use will tell how it holds up in the long run.

Performance and Power

Power is where the Milwaukee 6477-20 really shines. Its 15.0 Amp motor delivers 4,400 RPM, providing more than enough torque for most cutting tasks. Whether you're ripping through wet lumber or making precise crosscuts, the saw performs consistently and efficiently. The hardened steel worm gearing is designed to maximize torque, and it delivers. I used it on an extensive deck-building project, and it cut through wet wood as effortlessly as slicing through butter. The power never falters, even under heavy loads.

Ease of Use

Several features make this saw user-friendly. The depth and angle adjustments are straightforward and marked clearly, which simplifies setup for different types of cuts. The saw's oil site glass is a thoughtful addition, allowing for quick and easy oil level checks—this is crucial for maintaining the worm drive.

However, the saw isn’t without its quirks. Setting the blade to exactly zero degrees can be a hassle due to a rib on the base plate that obstructs the motor. This requires some fiddling and potentially even modifying the saw slightly to achieve a true zero-degree cut. Additionally, while using a speed square for cross-cutting lumber, I noticed that the base plate’s slight outward taper affected the accuracy of my cuts. These are minor inconveniences, but they can be frustrating during precise work.

Comfort and Handling

The saw’s weight, while contributing to its stability, can also be a drawback. At 15 pounds, it’s on the heavier side, and extended use can lead to fatigue, especially for overhead cuts or prolonged sessions. However, the ergonomics are well thought out. The grip is beefy and comfortable, allowing for secure handling even when the saw is running at full power. Despite its weight, the saw is well balanced, which helps in maintaining control during cuts.

Noise and Vibration

Compared to other circular saws I’ve used, the Milwaukee 6477-20 is relatively quiet. The slower RPM of the worm drive reduces the high-pitched whine typical of sidewinders. There’s still significant noise, as expected from a powerful tool, but it’s more tolerable. Vibration is well managed, and the saw runs smoothly, reducing operator fatigue.

Durability and Maintenance

Durability is a strong suit for this saw. The magnesium construction and hardened steel worm gearing contribute to its longevity. Regular maintenance, such as checking and changing the oil, is straightforward thanks to the oil site glass. However, the composite base plate, while durable, may need replacement sooner than a metal one if subjected to extremely harsh conditions.

Recommendations

Would I recommend the Milwaukee 6477-20 Worm Drive Circular Saw? Absolutely, but with some reservations. It’s a powerful, reliable tool that performs exceptionally well in demanding tasks. Its durability and robust construction make it a worthwhile investment for professionals. The few design quirks—such as the base plate rib interfering with zero-degree settings and the slight taper affecting accuracy—are minor but worth noting. For those who require absolute precision, these issues might be a dealbreaker.

For most users, however, the saw’s strengths far outweigh its weaknesses. The power, ease of use, and durability make it a standout choice. If you’re in the market for a worm drive circular saw that can handle anything you throw at it, the Milwaukee 6477-20 is a solid option that promises to deliver consistent, high-quality performance.