Rep Power: 266

I started to build my 1.4 cu. ft. box yesterday. The only problem is I suck at cutting up the mdf board. I only got one piece cut out and one side is a wavy. It goes from the length it should be to an 1/8th of an inch short on one end. If I would caulk it on the inside and use wood-filler on the outside to fill in the gaps, will I run into any problems?

Is there any suggestions on saws to use, besides a jiggsaw? Would renting a table saw be the way to go?

 
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Table saw will most definantly give you a straight edge. You could even use a skillsaw, with fine blade, and make a guide for it by screwing, clamping, etc a board such as a 2X4 where the guide is and lines up with the line you draw (hard to explain).

 
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I know what you mean about the guide. I will try that before I go out renting anything

 
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I agree, a sawboard is the way to go with a jizsaw or circular saw. my issue with jizsaws is the inability to cut a perfect 90 degree angle with the blade bending and such. It's great for rouch circular cuts though. I prefer the circular saw for straight cuts.

Here's a site about sawboards, if you're bored

http://members.aol.com/woodmiser1/sawbd.htm

 
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Pun intended?

 
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after trashing my basement, breaking various objects and taking a 15 minute break... I have come to the conclusion that jigsaws suck and that a circular saw with a 4' level clamped to the mdf board is the way to go.

 
Rep Power: 786

haha good ol geek humor if that is the case :P

 
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If you have time, and plan on cutting more, I think a great way to do it is to get a 1/4" thick aluminum rod and countersink/screw it to a board, it makes for a very nice saw board.

saw... bored of course

 
Rep Power: 310

Jigsaws don't suck. They serve a great purpose. However, your using it for the wrong purpose. My electric shaver kicks ***. I wouldn't cut my lawn with it though. Jigsaws arent' designed for cutting straight, even lines. Unless you make some sort of errrr, Jig. Pun intended.

 
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I wouldn't say jig saws suck either since I used one to completely build my 1.5 cu ft box that houses a Kicker L7.Just like they said you just use a guide using a straight edge and you should be alright.

 
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Check out your local high school's wood shop. Pay some kid ten bucks to cut them up for you at the dimensions you need.