On 23 Mar 2007 10:54:55 -0700, "Keith" wrote:

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.


Might be tedious to do. Sounds like a mortising bit will work well,
or if that's not practical then using a sharp chisel after removing
90% as you have been doing.