I use olsons blades and have no problems I stack my plywood 3 pieces very seldom do i loose a piece. but for some reason I am cutting a single piece of plywood I use a # 3 reverse blade. run the saw at a slow speed and let the blade the cutting.. On my Dewalt 788 when cutting i piece i run it at 3 to 4 speed.. I have used an under lament plywood for some projects and that is cheep 4X8 sheet about $13
I used an aquarem air pump for a long time, most scroll saws don't have a very good pump, I now have 2 DW 788 saws and have no problem with the air on either
I had an order for a wedding cake topper I quoted them a price no money down. i designed it and they said Ok . the next day they wanted to change the design OK so I got started and than they changed there mind again. z told them to forget the order and thru the finished part away I would not make the order at all. so they only had about a week to get a new cake topper. mSo now I get a deposit before I start.
Keep it you have too much work in it, will never get out of it what you put in it. great cutting. I never make a picture with out stack cutting it, use at least 3 pieces. some times one piece is bad with it chipping , you were lucky on that one.
Tight bond is the answer, but be sure that It is moated correctly. It is very difficultt to take app art after the glue is set., Tightbond is stronger than the wood .
I drill by drilling so far back out and clean the drill repeat this several times till you are thru, I have drilled thru steel with a.015 drill ( that is 1/64 drill using this peck Drilling system, and it works fine on wood also.