Trying to save $38 (x2).

Sucks that I’m not more “crafty”, and I don’t have a bandsaw.

Trying to replicate the SAI plate for my Hobie Outback. I’ll probably end up spending way more (not including ER copay- just kidding.  Safety first!!)

I have the material.  Almost an endless supply actually.  I’m using a shim we use between the timber lagging on retaining walls. (To allow drainage)

Cheap coping saw?

I made my own too. I think it was only marginally cheaper and definitely required a band saw and drill since I used aluminum.

Since it looks like you already have one, why not use it as a template for a router?  A simple jig-saw could cut most of the unwanted material away, then just template-router it with a flush-trim router bit.  I did the same project, but made my pieces more hexagonal to avoid the curvy sections.  Still used a router to round over the sharp edges, but course sanding would probably do it as well. 

Is that starboard/HDPE? 

Cheap coping saw?

This is probably the cheapest and safest option.  Hacksaw would probably give similar results too.  Just clamp it down as best you can - I would probably just clamp it direct to my workbench, leaving a bit of the material overhanging to cut, then reposition as needed.

You could also use pretty much any other wood working tools - what do you have on hand? 

I have a jigsaw, that I mounted upside down, under a table, and it works great (almost as well as a band saw), especially for plastic...

Jigsaw.  Coping saw.  Tried both.  Straight cuts are not my thing.  Haha. 


$38 each is sounding pretty good right now, but eff it.  I’m not in the biz of impressing anyone.   

Jigsaw.  Coping saw.  Tried both.  Straight cuts are not my thing.  Haha. 


$38 each is sounding pretty good right now, but eff it.  I’m not in the biz of impressing anyone.   

To get a straighter cut with a jigsaw, you can clamp some straight material next to your cut line and use as a fence.  You need to measure from the blade to the edge of the foot on the saw to know the distance off your cut to clamp the straight edge.  Jigsaws can be a bit fiddly - 60% of the time, it works every time, haha. 

Jigsaw.  Coping saw.  Tried both.  Straight cuts are not my thing.  Haha. 


$38 each is sounding pretty good right now, but eff it.  I’m not in the biz of impressing anyone.   

To get a straighter cut with a jigsaw, you can clamp some straight material next to your cut line and use as a fence.  You need to measure from the blade to the edge of the foot on the saw to know the distance off your cut to clamp the straight edge.  Jigsaws can be a bit fiddly - 60% of the time, it works every time, haha.

MMM.  should have tried that. Oh well.  My bespoke plates are strong.  I still have to jack up the drill holes tomorrow to really drive my lack of skills home.

My shop teacher just rolled over in his grave. 

Form follows function! 

No zooming in.