Do you still use a jigsaw and your homemade blade to cut outlines? I cut down the saw blade from a reciprocating saw to use in my jigsaw but tends to deform the cut a bit. It's hard to find a blade that is stiff enough to cut accurately.

I use a 6" Sawzall blade in my jigsaw to cut the outlines then a railrunner to square it up, or a hard block with sandpaper. (We have plastic Rail Runners for less cost as well)

Diablo 6 in. x 6-12 Teeth per in. Demo Demon Nail-Embedded Wood Cutting Reciprocating Saw Blade (5-Pack)
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