Thanks Newtooth. My big concern here is the melting and gaulling of the plastic on the blades. Heat and friction will be the real enemies here and because of this, I need to keep the blade speed and feed speed to a minimum. I've had some experience turning plastics and have seen what happens with high speeds. Even razor sharp tools can cause friction and melting of the material. The sander could also be problematic due to the friction and heat build up, that and I don't have a hand held belt sander
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I'd first recomended going for a full sized piece and then a smaller one with the seam towards the back, but my friend will be setting this like a penninsula sticking out from one wall so that you can walk around it. Because of this, he wants the seam right down the middle. As the seam will be visable towards the edge, he wants to keep a semetrical look to the thing.
So, if I read this right, you are saying that rather than take these long cuts on the TS or BS, that it would be better, due to size and wt. of the material, to do this with a Circular Saw or jig saw, then clean the cut with a router. That's probably a good way to go. I have good straight edge jigs for both my CS and JS. I'm going to play with it a little on the waste end to see for sure.
Thanks for the info.
_________________
Frank
WWACOAUX#1
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