Hi there, I used a (simple) jigsaw of Bosch and cut the molds out just a mm bigger than the line. looked great and little to sand. all you need is a steady hand.
Goodluck :D
Poll Question: Jisaw or bandsaw for cutting molds
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Rick Moulton
Cutting Molds
Here's a trick that you can use to cut absolutely identical/symmetrical molds for each station for symmetrical canoes (a variation can be used for asymmetrical canoes). Cut the molds using a band saw or jigsaw to within 1/8" of the line. One one side of one mold sand, plane, or surform to the line. Clamp or screw the two molds for the same station together making sure the midlines and baselines of the molds are precisely aligned. Use a flush cutting router bit (bottom bearing) to trim the rough cut mold to the planed mold by riding the router bearing on the planed mold. You now have one side of 2 molds cut to the line and identical. Flip one of the molds front to back on the other mold and re-clamp. You should now have one rough cut and one final cut surface adjacent to each other on either side of the clamped molds. Repeat the procedure with the flush cutting bit. This is actually faster to do and far more accurate than individually sanding and planing each side of each mold. For an asymmetrical canoe you could use some 1/4" masonite or plywood to transfer the pattern from one side of the mold to the other using a flush cutting or pattern cutting bit.