: I am now ready to do what seems to me to be the most intimidating step of the
: building process so far, cutting out my hatches.

: First I have a few questions: (Honest this is not avoidance)

: The deck is sealed and glassed(4oz) on the inside, raw okume on the outside,
: I will be cutting from the outside. I will masking tape the outside before
: I cut.
: Should I seal, and/or glass the outside before I cut or not?

: Should I set the jigsaw to cut with a rotational motion or straight up and
: down?

: The saw, Bosch, has a small clear plastic insert that fits closely around the
: blade to reduce chipping on the upstroke but if I cut with a blade that
: cuts on the upstroke am I asking for trouble? It seems to me there would
: be more tear out if I cut on the downstroke but I could mask underneath.

: Could some of you woodworking brainiacs help me out?
: Thanks.

: Yours nervously,

: Ken

If you seal your wood before cutting out the hatches the plywood may be less likely to splinter.

Set your saw with just a straight up and down stroke. Be sure the dust blower is on though. I have a Bosch saw also (the best) and know what you're talking about. Get a metal cutting blade for your saw. It has a very fine tooth that will make a very smooth cut.The more teeth in the wood the smoother the cut. Still use the plastic insert in the foot. Set the cut speed to 4.

Lay out masking tape where you will draw you line. Draw a fine line. Take the smallest drill bit you have and drill four or five holes on the line very close together. You will push your saw blade into the holes to start your cut.

Cut on one edge of the line. Set your feet and hands so you're comfortable and get the saw cord out of the way. Cut about 1/4 of the hatch, stop and readjust your feet hands, power cord and lights if need be so nothing will impede your making a smooth cut. Do the next 1/4 and so on. Don't rush.

You'll have a little leeway to sand any slight irregularities out so don't worry.

Sorry I haven't contributed much lately to the BB. I've been a busy working on finishing a new prototype kayak for next Saturday's "Meet at the Beach".

All the best,

Rob Macks
Laughing Loon CC&K
www.LaughingLoon.com