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  • #16
    Seems like you got the Dremel covered, now on to the raggedy cuts:

    Are you using any thicker wood on the top and bottom of your stack? That 1/16 plywood can be very floppy, and if it's not supported, even in a tall stack, it can work up and down making gaps in the middle. Once a chip gets in there, it holds the layers apart and it just gets worse.

    When I'm cutting very thin ply -- or paper or cardboard -- I use a 1/8 plywood layer at the top and bottom of the stack, and make sure the whole thing is squeezed down tight. I hold the stack together by taping all around it. The top and bottom boards keep the stack tight at the middle as well as around the edges.

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