The straight edge sounds like a great idea - I think I have a piece of 1/2" angle iron that will work well for that - if/when I have to make some long straight cuts.
The plywood patterns also sound like a good idea - especially if you're making more than a couple of parts that are the same shape.
Unfortunately, for the project at hand I'm making a lot of one-off or two of a kind parts, so the time investment to make patterns is a bit more than its worth.
I just have to do some more practicing and develop a steadier hand to get the smoother cuts I'm looking for. God willing, the weather this 4-day weekend will stay dry enough to let me get some real practice...





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