This project required a new tool!
a mini-powersaw.
(see this thread for more details on the saw.)

Got the speed controller to slow it down.
made by "Grizzly" and ordered from amazon.com
a setting of "5" works perfectly.
(I put it on the floor when sawing)

The saw does lose some torque at slow speeds..but for cutting plastic, a speed of "5" is fast enough to cut the plastic without bogging down the blade, but slow enough that the plastic doesnt melt..

I made a new table from a sheet of 1/4" thick model airplane plywood..
I glued 2 wood rails to the bottom, that mesh with the slots in the saw table..I put the scary big-tooth blade on the saw to cut through the wood to make the thin slot..the "zero-clearance throat plate"

about the blade..
I was thinking that 4" saw blades would be fairly common..
i went to Harbor Freight first (where I bought the saw)
they had TWO blades available for purchase...both identical to the two blades that came with the saw!! [V]
So I went across the street to Home Depot..they had NO 4" saw blades at all! I was honestly surprised!

So I went home, dejected, and tried out that smooth "Dry Diamond Blade" that came with the saw..it works great!!
slices through styrene like butter!

I used some straight edges, laid them against the blade, and drew some lines on the table for reference.
A piece of thick(ish) brass stock acts as a fence..clamped down at the proper distance:

and its time to try it out!!
here all the pieces ready to cut:

first cut..I need to slice one 1mm from the bottom of all four coach sides..safety glasses on, line up the fence, and slice!
I stopped the saw so I could take some pics..

the saw leaves behind some plastic flash..that easily snaps off..
a quick once-over with an x-acto blade cleans up any left over flash,
and done!!
four long cuts nice, even, equal and straight!
SO much better than sawing by hand!
im very pleased..this will work!

the pieces so far, with 1mm off the bottom:

next step, cutting off the tops of the coach sides, right through the middle of the top windows..
 
 
 
 

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