avoid splitting when driving pocket hole screws along the grain into an end piece...

[Pierre Vallee]

Even when selecting the correct setting and drill bit measurement, and screw length and type, have experience some splitting or crunching in the wood at the end of a piece. This occurs when pocket holes are in the side supports of a chair backrest and seat supports, and screwing into the ends of the slats. It may have to do with the moisture or lack of in the wood but it’s probably due to the holes being very close to the end on the slats. Anybody have any suggestions? I’ve tried pulling back a little on the drill bit to make the screw shoulder back and reduce depth of the screw but this could compromise the strength. Ideas anyone?

[Ken Darga]

Screws entering  too close to the end of the work-piece, can result in splitting.

Splitting can also occur, when the screw enters the end grain, close to the end or edge of the work-piece.

  Look closely at the ends of plywood---note the laminations---screws entering between the laminations can cause the joint to separate.

Make this simple test---

drive some practice screws into the laminated joint of the plywood, and notice what occurs---

the joints will separate.

  One way to reduce the splitting problem, is to use smaller dia screws---#6 vs #7.

  Another is to add a pilot hole---which can be accomplished with the proper drilling tools.

  Locate the screws so that the point of the screw is directed ‘’inward’’---

away from the end of the work-piece---

vs the point of the screw going ‘’outward’’, toward the end of the work-piece. 

[Pierre Vallee]

...if you have the correct settings (jig and drill) for the stock you use, all should be centered and splitting shouldn't occur unless of course you rush things and do not have the correct screw.

...I don't use plywood much, what was happening is with solid SPF

...smaller screws may work but a) are they available as auger and type, b) application. Would have to see and test

... pilot holes are tedious and you shouldn't have to do this; after all, that's the idea of pocket hole systems right? As a test it could be interseting to see however

Thanks, those are good thoughts