Drill your starter hole and proceed as before but STAY ABOUT 1/16TH AWAY
FROM THE LINE. Clean out the scrap with a mallet and sharp chisel. If you
have one, use a corner chisel to get nice square corners.

"Keith" wrote in message
ups.com...
I tried to cut a square hole with a jigsaw. I flat out failed as the
cut had a wavy appearance. I am using nice Bosch jigsaw.

What I did was to drill a hole and then approach the line. I had a
aluminum straight edge. I found that the angle I cut had caused the
blade to bend.

I have a new piece of stock and I am going to try again. I did
decide to ensure the blade will not bend yet I keep thinking I will
have the same issues. I searched the groups but did not an exact
answer. Just looking for some guidance.

Thanks.