I use an inverted jigsaw with a fine metal-cutting blade, to cut out
upto 48 pieces from a 100mm x 220mm board. Width of kerf about 2mm, the
accuracy of the cut depends on your manual dexterity ( a guide could
help here). It works fine for my 16-out-of-a-board but I'm looking for a
better approach for the 48-ers (I shall check out the Dremel approach
which could be good for that...) SAFETY NOTE make sure you mount the saw
so you cannot inadvertently make contact with the oscillating blade
mountings etc and rig up a cover to protect you from the oscillating tip
of the blade, so only the edge of the blade is exposed; this greatly
reduces the safety hazard.

I clean up the edges with a small belt sander. Takes around 15 seconds
to sand 4 sides and round off 4 corners.

Stuart

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