Cicular Saw Plunge Cuts
I'm working on a project where I need to make multiple, short plunge cuts (~40) in 2X lumber, for making oval shaped hand holds in the stringers of a ladder. The cuts will be part of removing waste, to be finished with a straight router pass to size, followed by a 1/2" radius roundover bit. The plunge cuts will be 11" long and as through as I can get them.
A couple questions:
1) Because I want the cuts as deep as possible, the blade needs to be extended, potentially to its maximum. This requires the saw start the plunge at a fairly steep angle. The way my template is built, there is little "guidance" at the start of the plunge. My question is, should I make some vertical guides to help keep the saw lined up with the guiding side of the template? Such a vertical guide would be at the rear of the saw base plate and might need to be 3-4" high. Or, do I just eye-ball the alignment as the plunge is started?
2) Should I set the saw to its desired depth (max.) and make the cut full depth in a single pass, or set the saw depth at less, say 1/2 max. and take two passes? I see some potential issues with multiple passes?
The circular saw is a Skil Model 77 worm drive. I am having the saw blade sharpened before tackling this.
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