Join Date: Jun 2002
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Fire damage to my bowsprit!
Indeed, inexpensive but fresh skil-saw blades are perfect. The ideal surfaces inside the kerfs will be a little rough and maybe even slightly hairy. Avoid good carbide blades, which could leave lots of polished wood surface along the kerf''s sides. And burning is the worst form of polish, so avoid that, too. I''d get a dozen cheapies and change whenever the sawing got noticably stiffer.
Do make your guide/rip fence robust and accurate if you intend to chase the epoxied kerfs with second cuts for splines. For those cuts I would use a decent carbide blade, a little wider than the disposable blades, but still an alternate tooth bevel cross-cut profile for zero splintering. Oh, and mask up (at least) if you''re sanding or sawing the epoxy!