[JustinD]

I strongly believe wire cutting is a hobby myth.There is no evidence I have seen of any major manufacturer using a wire cutting method. I would readily assume that Donruss rough cuts were caused by use of the same cutting machines as O Pee Chee. The hand process used by workers was cut using a “splitter” which was a circular blade cutter. There are existing interviews with ex workers that verify that method.

A splitter had rotary discs (smallish rotating circular blades) that did the vertical cuts and I believe a single cutter drop blade for the horizontal. This is why most rough cuts are on the right-left and not top-bottom. These machines were very inefficient as they handled a single sheet at a time. When used properly and with new blades the cutter was quite good. However, when workers would attempt to meet printing deadlines the machine was often used to cut multiple sheets at once to process faster. When done in that way the blades dull faster and the bottom sheet or sheets of a stack would suffer from a rough cut. These printers would also not want to stop production to change blades until it was quite literally not cutting. There were antidotes from workers on o pee chee’s machines actually hand separating cards at times that didn’t cut completely.

Rough cuts were simply a quality control issue within the factory. Topps was stricter on maintaining the machines and why rough cuts are less common in most issues. I do not know if Donruss contracted a different processor for the 1981 issue as it was their first large scale release after so many years of just smaller non-sport runs or if they just had difficulty learning the mass production of the baseball and golf issues of the year. The end result was a set that had numerous quality issues with collation and production flaws (I still however admit to having great memories of that 1981 year and the introduction of the Donruss and Fleer competition).

Like OPC releases, Donruss and fleer both have cutting issues that I think add to the charm of the sets and do not seem to affect grading in most circumstances.

Just as a visual aid, here is a photo of a splitter operator at OPC. You can see the worker stacking the completed cards at the end of the cutter. These utilized a gripper to pull in the sheet which was pulled through the blades and stacked as shown here. This photo is interesting as it seems to show the horizontal cuts were first and the strips were fed through the vertical cutter and stacked for packaging.