How to smooth out uneven cut?

[soulblazer28]

Well, being a complete amateur and not using any straightening techniques, my jigsaw cuts were less than perfect. Most of the time it doesn't really matter because the defects are hidden.

The place where the control box sits is a problem though.  it has small peaks and valleys and causes the box to sit unevenly.  I know I could use a router and a flush trim bit but now that it is assembled, I'd rather not go that route (no pun intended).

I take it that sanding would take too long, I am thinking of a long file and just file it flush. But I am wondering if it will do more harm than good.

Can anyone suggest anything worth trying?

[GregorDV]

I would suggest re-cutting the line with a jig saw.  This time, clamp a fence to your piece of wood. 

Assuming your cut edge is on the right hand side:
First, put the jigsaw on top of the CP piece at its lowest point (the one farthest from true) and mark where the guard ends (the metal piece that protects the blade) on the left.  Take a known piece of straight wood and place it so its right side is just on the mark you made.  Then take a combination square (or any good known right angle), and align the rest of the straight wood so it's square to the edge of your CP.  Clamp both ends, then run your jigsaw down the line, making sure that the edge of the jigsaw's guard stays flush to the fence along the entire cut.  This should cut away a sliver from the CP that will leave you with a nice, clean edge.

[DaveMMR]

Personally, I avoided the jigsaw when possible.  A decent circular saw can be had cheap (I got one for $30 at Home Depot) and even when cut sloppily, is still better than a bad jigsaw cut. 

You still want to use a ripguide or fence or whatever, but you'll do much better with the ole c-saw.   

[shardian]

I have a belt sander that I straighten out irregular cuts with for pieces lessthan 2' long. If you dion't have one, don't go out of your way to get one though.

[RayB]

Work out. Do crunches.

OH "CUT"!! I read the subject and thought it said GUT!

[soulblazer28]

For this project I bought all the mentioned tools, router, flush trim bit, jigsaw, circular saw, and sander.   

Thanks for the suggestion gregor, I will consider it and it looks to be the easiest way.  Not only will it help get a straight edge, but the control panel is so high (using Lusid design plus castors) that I might do well cuttin an inch or two off the control box saddle (for lack of a better term).  Its great for me but I'm 6'1" and most my friends are 5"7 and down

[GregorDV]

I was assuming a jigsaw was all you had.

You probably want to use the circular saw with a fence for all of your straight cuts.  Don't forget that a circular saw's blade has a non-trivial width.  Good practice is to draw your line with a straight edge and a pencil, then put x's on the side that you don't care about.  When you're sawing, make sure that the inside edge of the blade is flush with the cutting line, and that you're removing wood on the side with x's.  Don't try to run the blade straight down your line or all of your measurements will be 1/16" off (says the voice of painful, adult-language ridden experience).

I'm prototyping a new CP; I'm 6'0 and my wife is 5'4, and I want it to be as pleasant an experience as is possible for her.  I made a quick'n'easy CP out of plywood screwed to some braces, hooked it up to a spare PC, and I'm letting her play with it at different heights.  No matter how perfect I make it, though, I think the MAME cab is going to be a net loss of marital capital.   

[DrewKaree]

If you can actually get sandpaper on it and don't want to go through the hassle of recutting it, get a 2x4, some large sheets of sandpaper, and some spray adhesive.  Cut the sandpaper into 3" strips.  On one of the edges (that's the 2" part), spray it with the adhesive.  Attach the strips of sandpaper.  Sand. 

It really shouldn't take too long at all.  You could use a rasp or a plane, but I'm thinking you'll just end up with different peaks and valleys spaced further apart, and frustration on your part. 

[rdowdy95]

Guys I am a total noob, but what is a fence.  Can you give me a link so I can see a pic.  I haven't strated my project yet, but got all the tools.  I do have a straight edge metal ruler, but would like to know more about this fence.

[GregorDV]

Here's one fellow's guide on doing a fence _right_ with a circular saw.  Of course, he's measuring to the center of the blade for cutting wood in half.  Most of the time you want to have a piece of a specific size.
http://crumleydotorg.chattablogs.com/archives/025070.html

The basic idea is just to have a straight edge (typically a piece of wood) that you can slide the edge of your saw down to guarantee a straight, accurate cut.

[DrewKaree]

Guys I am a total noob, but what is a fence.  Can you give me a link so I can see a pic.  I haven't strated my project yet, but got all the tools.  I do have a straight edge metal ruler, but would like to know more about this fence.

Make an almost fool-proof version for your circular saw.

http://forum.arcadecontrols.com/index.php?topic=43568.0

[GregorDV]

Yeah.  Ignore all that stuff I said and listen to him.  I like his plan better, and will be gettin' me some of that.