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  jigsaw with guide to start ........
  Posted by: pilotwingz on Apr-15-13 10:39 PM (EST)

-- Last Updated: Apr-15-13 10:48 PM EST --

..... the jigsaw should get you within 1/16" - 1/8" . Then finish up with a belt sander to the composite surface .

You can use your finger as the guide for the jigsaw , I would without any more thought (grip the base plate and let your finger edge ride along either the inner gunnels surface or outside hull surface , same with circular sawing) , but an actual guide will likely give you more confidence .

The jigsaw cutting will move slowly but it's a one time pass and your there . Use new sharp blades in the saw and preferably "no set" tooth blades . A jigsaw that has 3 or 4 blade action settings will be helpful also ... these type settings allow the blade to not only go up and down but allow some forward and backward movement of the blade as it goes up and down , occilates .

If you have perfect confidence , you can cut the exact glue line with the jigsaw , I could but you might be more comfortable cutting to within a 1/16" or 1/8" and finishing with the belt sander .

A router is a fine tool but the job you are attempting is too tricky for the router . You'd have to use a guide on the router and that's a good thing , but the problem will come in trying to keep the router from tilting because you haven't enough flat surface to run it on . if it tilts towards the inside you just chewed the a hole in the hull , and a router has exremely high rpm's and must be handled with perfect touch and coordination .

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