Using a slightly modified version of my bonesaw-building technique (I had foam leftover). This time, a foam core with the plastic on the OUTSIDE, to save time w/the gesso.

21" long, this feels like a good size finally.

A note on the pieces, though -- the cutouts I choose were based on the size limitations of my materials. I really recommend going full teng on the blade, i.e. your core piece should be the handle AND the blade.

The ubersaw blade is a lot more prone to wobbling, especially once you get the syringe on, and you don't want a weak join where the blade meets the handle. If, like me, you can't go full teng, I suggest reinforcing the join with a few strips of fiberglass mat and resin. I ended up reinforcing almost the entire outer edge of the handle this way, too.