A question about jigsaws and tools in general

[grumble]

After reading Project Arcade and a ton of project walkthroughs I have a concern. I noticed that in cutting the angled back panels most of you are using a jigsaw that can make 45 degree cuts. Unfortunately my Black and Decker jigsaw doesn't have that feature. So I'm wondering how hard it would be to angle the edges with my circular saw (which does tilt). Any advice?

Also could someone recommend a good router. I'm still reading but I was wondering if I should get a plunge router vs. a non-plunge model. What is the difference functionally? Any other tool recommendations would be appreciated

[DrewKaree]

unfortunately my Black and Decker jigsaw doesn't have that feature. So I'm wondering how hard it would be to angle the edges with my circular saw (which does tilt). Any advice?

are you SURE about that B&D?  My old one required an allen key to loosen the foot plate, but it would do angles...regardless, your circ saw will work just fine as long as you go slow and have a fence to work against (long piece of angle iron will suffice)

Also could someone recommend a good router. I'm still reading but I was wondering if I should get a plunge router vs. a non-plunge model. What is the difference functionally? Any other tool recommendations would be appreciated

Depends.  Will you use this for anything else?  If you plan on using it a lot, get at least a 2 hp model or larger.  If you only plan to use this for your cab, consider renting one.  A plunge can be VERY poorly made, and for your purposes, probably aren't necessary.  The only thing you might want to plunge-cut are your button holes, and you can get a forstner or spade bit to work just as well.  A fixed-base router is going to serve you better, and will probably be better made (which will also mean probably more expensive, welcome to tool-buying  )  Technically speaking, you could do plunge cuts with a fixed-base router (although nothing requiring a straight side).   I recommend Milwaukee first, Porter Cable second, and DeWalt/Ryobi/Bosch/Makita/Hitachi last.  If you're looking for BUDGET budget alternatives, B&D makes DeWalt, for what that's worth.  Sears will probably be decent, too.  

Home Depot has a Ryobi Kit with three interchangeable bases for $150...dunno about quality, but it's a pretty decent buy for the price.  

Buy carbide bits.  It'll be worth the expense.

[Mameotron]

Here is a link to a fixed base (not plunge) router.  I'm not endorsing this router, it's just a nice picture.

http://www.grizzly.com/products/item.cfm?itemnumber=H2401

The router bit goes on the bottom and you adjust the depth of cut by adjusting the bit further up into the router for a shallow cut, and protruding more out of the base for a deep cut.

Here is a link to a plunge router (again, no endorsement).

http://www.grizzly.com/products/item.cfm?itemnumber=H2854

You can see that the very bottom part of the router (the base) is connected on two shafts under spring tension.  The springs push the base away from the router, giving you the minimum depth of cut (usually so much that the bit misses the wood by 1/2 inch or more).  You adjust the depth of cut by pressing down on the router handles, bringing the bit deeper into the work.  There is usually a thumb lever for locking it into place when you reach the desired depth.
The reason for this is so you can adjust your depth "on the fly" and don't need to stop to readjust your depth.

There are good arguments for each type of router, and ultimately it's going to be what you like best.  I prefer the plunge router myself ( I have both kinds), but it does take some getting  used to.

I'm at work, but I can later post the specs for my routers.  The plunge router I have is a Skill brand I got at sears 10 years ago for $35.  They stopped selling that model and now have reissued it as a "classic" for $65.  Same exact router.

[marsmarvin]

General advice:

Use a circular saw for all cuts that you can.  Make sure to always use a fence - like a 2x4 - to guide your cuts.  Some cab builders like to use the jig saw for everything - spystyle is one of them

http://spystyle.arcadecontrols.com/index2.htm

but I think that method is slow and results in inferior cuts (maybe I just don't know how to use a jig that well, but I now have a definite preference).

Of course there will be times and places you have to use the jig saw, but I prefer the circular saw, even on the angled cuts.

With the circular saw always make sure you adjust the depth of your blade for the board you are cutting.  This helps avoid kickback - which is dangerous and can also ruin a good board.

When cutting the hole for a trackball use a saw bit for your drill.  A 3" saw bit works great for a 3" trackball.  A 3" saw bit also works good for cutting the hole for cab fan(s).

[hyiu]

for angle cuts, my personal preference is USE CIRCULAR SAW AND A GUIDE (or fence...)

I have tried angled cuts with jigsaw and its kinda off.... (well... my skill is limited...) but in my personal experience, angled circular cuts are easier....

good luck...