: As a professional cabinetmaker I can heartily endorse the Dewalt jigsaw. It's
: kinda expensive, but will last a lifetime.

: I plan to try out my Dewalt 14v cordless circular saw for cutting out my
: 1/8" panels, in the next day or two if the weather cooperates. It
: sports a 5 3/8" dia. blade, which I will set to a depth just over the
: panel thickness. This per CLC's advise to cut down on wandering. Will post
: results as soon as they are in.

: Question for other Kurt: Did you use 1/4" ply on your Grebe? I want to
: use a router w/flush bit for cutting my panels, but am skeered that
: 1/8" isn't enough for the bearing to operate safely.

: Cheers,
: Kurt

I used a similar 1/4" template for the 1/8" Severn panels. The Grebe template in the pictures is 1/4" lauan. I haven't cut the panels yet. I used a pattern guide bushing attached to the router base rather than a flush cut bit. That's why the pattern was made 1/4" undersize. The appropriate bushing and a spiral straight bit will make the actual panels to the correct size. The bushing lip is about 1/4". I filed it down slightly so that it won't hit the panel while routing. You could use 1/8" for the template, but it wouldn't leave much of a lip on the guide bushing. Once the template is made, exact copies of the panels can be routed in minutes rather than laying out and cutting each panel by hand. My router table insert will also accept the guide bushings. I'll likely try it on the router table next time.

Kurt