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Lightly Sand and Square Inner Corners Once the parts are all cut out, go ahead and lightly sand the pieces. this is just enough to remove any tear-out caused by the bit. Also, you will want to square cut the rounded inner corners on the notches present on the sides.

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Sand some chamfers to the inner blade edges as shown in the plan. Round off the leading edge. Cut out the two top and bottom circular blade stops from 3 mm Depron and paint the blades and blade stops. Put a small mark on the top of the blades at the inner edge, 6 mm / 0.24" from the leading edge.

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