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  • If the cuts are most visible from the inside then it will be tricky to do a good cut with any power tool once the carcasse has been assembled and there is more of a chance of a cock up occuring if you make the cuts before assembly (it can be done though).

    Jigsaw wise you could use a push blade and cut from the side that needs a neat edge, giving the edge of the cut a light sand with ~ 120 grit sandpaper. You could also try a laminate blade (very fine bi-directional cutting) in my experience you need to control the speed VERY carefully with these.

    To be honest in this situation my preference for doing this or any other cutting where it needs to be a good, clean cut for example scribed decor panels would be a really sharp fine toothed handsaw. However your sawing technique needs to be good - keep your wrist, elbow and shoulder in line

  • Thanks @Bobbo
    Quality handsaw sounds the least risk at the best price point. I have some niche CNC kit here that I can use to make some 1:1 templates in cardboard before making the final cuts so hopefully reduces the chance of a cock-up.

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