Difficult Cutting Problem - What Tool Would You Use?

Discussion in 'Boatbuilding' started by CatBuilder, Nov 6, 2011.

  1. Boston

    Boston Previous Member

    make a jig for that beam saw and cut it from both sides. Ive done lots of odd ball cutting and if you want accurate joinery you gotta use a jig if your cutting anything irregular in shape.

    And yes you can work wonders with a chain saw if your well enough practiced but an amateur with one is damn dangerous specially on a plunge cut like what your describing


    it can be a simple plywood form like a box or something that slips down over the offending piece. Lay it out on the jig and do a practice piece, once you've got it down then try it out on that million dollar looking dagger board.

    Best of luck
  2. Dave T
    Joined: Sep 2011
    Posts: 250
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    Location: Anamosa Iowa and North Buena Vista on the Mississi

    Dave T Senior Member

    I would screw a metal guide to the back side such as some 3/4" by 1.5" tubing or what ever else you have handy put a little lube on the tube and if your careful the sawsall blade will follow the tube and your cut will be square remove the screws and fill the holes. I like the picture I tried to zoom in to see the dagger board.

    Dave T
  3. CatBuilder

    CatBuilder Previous Member

    If only I *were* an amateur with a chainsaw... I'd probably be a more pleasant guy! :D
  4. Boston

    Boston Previous Member


    I've just seen a lot of accidents. And my condolences for the experience. Its kinda a curse knowing how to build a "logy", once your labeled competent with a chain saw, if your not careful, its all you'll ever do. Back in the day I'd get calls about once a week, someone building something with log accents.

    Anyway do the jig and the beam saw. A sawsall will never give you a very nice cut, its more of an eraser than anything else.

  5. CatBuilder

    CatBuilder Previous Member

    Yeah, I grew up rural (read cut, split and stacked dozens of cords of wood for the parents), then used my current chain saw as my only source of heat, living aboard full time for a few winters in Maine. New England. You know how it goes! :D

    I don't know where this thread came from again (it's old), but I ended up just using a hole saw on the 4 corners. I went far enough through that the pilot bit popped out the back. This gave me a true center to go at it from the other side with the hole saw again. Those round cuts then fell out...

    Then I used a circular saw to cut part way through the glass/foam on each side, connecting the 4 corners (which were already cut out by the 4 hole saw cuts).

    From there, I used a hand saw to cut the remaining foam in the center of the board's core... tidying the whole thing up with a belt sander and a bit of hand sanding in the hard to reach spots.

    I guess a jig may have been faster, but those boards are now done.
  6. Boston

    Boston Previous Member

    why is it that most of the time nudist are exactly the people you don't want to see with there cloths off. :D:D:D

  7. CatBuilder

    CatBuilder Previous Member

    Ain't that the truth!!!:D
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