On Oct 18, 11:51 am, Jay Chan wrote:
On Oct 17, 10:38 am, Jay Chan wrote:

I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

I know I will not be using a grinder (with a cut off wheel) because I
cannot see how I can keep the dust down using it.

My circuit saw doesn't have a dust port. Would the result be much
less dusty if the circuit saw had a dust port? If it will be less
dusty with a dust port, it will be my first choice because I can cut
very straight using a circuit saw. But I doubt it because I have a
feeling that all the rotary tools kick up a lot of dust and will be
hard to control dust.

Is a jig-saw much less dusty? I know I would have a hard time using a
jig saw to cut at 45 degree angle. But this should not be a problem
because I am cutting at a 90 degree angle anyway. I may have a hard
time to cut a straight edge using a jig saw. But I think I can fix
this by using a straight wood board to guide the jig saw.

Is a reciprocating saw less dusty? Then I can use it to cut at any
angle, like what the guy in ShipShape TV used to cut a hole on the
floor of a boat and keep the cut edge at a 45 degree angle. But I
have a feeling that I would have a hard time to keep the cut edge
straight using a reciprocating saw.

Any other better power tool? I welcome any suggestion and experience
that people want to share.

Thanks.

Jay Chan

Thanks for everyone who has replied. I appreciate that.

Because the deck is relatively thick (like slightly more than 1/2"), I
doubt that a dremel will be able to handle this. But this gives me an
idea. May be I can use a router with a straight cut bit. I didn't
think of that. I have a router that has a dust port and transparent
plastic covers blocking all the openings. I "think" it may do a good
job in collecting all the dusts that the router. The downside is that
I am "very" sure that it will generate a ton of dusts and may clog the
filter in my shop vac very quickly. Therefore, I am very hesistate to
try this. At the end, I think I will pass.

I went to Sears to check on their circular saw, and I cannot find any
that has a dust port. I guess the idea of putting a dust port in a
circular saw doesn't work quite well. I remember my circular saw
kicked up a lot of dusts when I used it to cut a small area of the
floor. I think I will not try it again.

Seen like I should use a jig saw with several new carbide saw blades.
In areas where the floor is resting on a stringer, I will not be able
to use a jig saw. For those areas, I will have to use a hand saw or a
reciprocating saw.

Of course, I need to wear a protective suit, gloves, face mask, and
tape around all openings. And thanks for the tip of taking a "cold"
shower instead of a warm one (I didn't think of that).

Thanks again for the tips and for sharing your experience in this
issue.

Jay Chan- Hide quoted text -

- Show quoted text -

I end up changing my plan. Instead of cutting out the entire deck, I
have decided to repair the deck in place by patching the many areas in
the deck that have rotten core.

I found that the console is sitting on top of the deck. I didn't see
this from outside; I only saw this details when I got inside the
console and examined the connection between the console and the deck.
If I wanted to remove the deck, I would have to remove the console
first and this would involve disconnecting many wires and control
cables. Because I didn't feel comfortable of disconnecting and re-
connecting the steering cable, I decided against removing the deck.

I am already done with removing all the rotton core from the deck.
Unfortunately, cold weather is coming. I will have to resume patching
the deck next spring when the weather will be warmer.

Despite the fact that I haven't cut out the deck. I still believe that
a jig saw or a reciprocating saw will be a minimum dusty way of
cutting fiberglass. I based this on my experience with using a "flush
cut" power saw from Bosch (my new toy) to cut out the outer skin of
the fiberglass deck. The blade of a flush-cut saw moves forward and
backward just like a reciprocating saw, and I find that this power saw
generates very little dusts, and the dusts are sitting right next to
the cut instead of kicking up toward my face. If this flush cut power
saw generates very little dust, I am sure that the similar operating
power saws like jig saw and reciprocating saw will not be dusty
either.

Jay Chan