[phatmonk]

I bought a 1507 model Bosch jig saw and the best metal cutting blades I think they are 20tpi.No seperation problems.I got the plate from Dragonplate 1/8 inch 3.17mm 15 layer carbon fiber.I put the smooth side up and the textured side down then finished the bottom with 15 coats of polyurethane sanded with steel wool.At first I tried using my 20 year old BD jig saw and it did overheat the cf that made it seperate.The Bosch jigsaw made the differance that made it possible.I did tester pieces to make sure that it would work before I even started the chassis along with testing countersinks.I am going to do another chassis in SSg 4mm silver graphite next.
As for the weight savings that wasnt realy a issue I wanted a chassis purpose built for electric.Its wider than the original and no extra holes with organized battery mounting holes.