went through all 4 batteries again this morning and only managed to make one complete cut (12" long cut). on the sides of the blade, it almost looks like the aluminum is melting to it, might be what's binding it sometimes, but the blades are listed as metal cutting blades, but they seem a bit coarse to me, but then i don't use saber saws on a daily basis. i would have thought they would have been a finer tooth. i finished my cut with a hacksaw. made for a nicer cut too. i'll be heading into town later this week and will take a piece of plate with me to the metal shop and see how he would cut it - mainly to see how it would turn out. if it looks close to how the edges look on the stock pieces i have, i may have him cut a second set of parts for me. anyway....... i have the parts cut out to make one of the housing and will try to start drilling and tapping the pieces together. I was originally thinking of using a piece of 1/4" for the base and for the rear plate and a piece of 3/16" for the front being as i have to make sure there is some clearance between the plate and the sprocket and chain coming off the motor. i think 1/4" would have worked, but would have been tight. so i thought, why chance it. if i have something together this evening, i'll take pictures and post them Chris, _Odyssey Slipways_ (http://hometown.aol.com/odysseyslipways/index.html)
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