: Bret

: I would stay away from particle board if possible. It will work, and will cut
: o.k. with a jig saw, but it tends to be a bit flaky with screws (they will
: pull out the grain if over tightened ) and it is heavier than plywood.
: Plywood will hold both screws and staples better, it's lighter, and cuts
: easier. However, it costs a bit more. I wouldn't use less than 5/8"
: and prefer 3/4" for stability. As to cutting with a jigsaw, the only
: inherant problem with them is the fact that the blade is
: non-supported/guided at the bottom, and therefore tends to drift outward
: of your cuts on curves. You can plan on this and make the underside of
: your plywood the part facing the cockpit. In otherwords, when you are
: cutting the aft forms, cut with the cockpit/facing side down. When you are
: cutting the front forms, cut the with the cockpit/facing side down. That
: way the bevel will be facing the end forms and you will have more strip
: contact on your forms. You may still have to do some sanding or filing,
: but that will get you going in the right direction.
: Hope this helps!!

: Rehd

Oh, if you decide, do to cost, that you have to use particle board, do not buy the standard stuff. Ask for the underlayment quality. It's harder than the hinges of ......... but, will work for what you want. The standard stuff is too soft and won't hold anything. You can tell the underlayment as it comes in 5/8" and is solid all the way through. Not solid outside and loose inside. Use a resperator when cutting or sanding this stuff as it is wood chips in formaldihyde glue. Not good to breath. A simple particle mask will do.

Rehd