: What are the tradeoffs to consider when selecting the material to use for the
: forms for a Great Auk? I will be cutting them out with a jigsaw only (I
: don't have ready access to a bandsaw and/or disk sander) and want to
: select the material that works well with a jigsaw but also has good
: staple-holding properties. Any recommendations for me?

: Thanks,
: Bret

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