I haven't had to toss many but I lost a project when it fell and broke after about 30 hours and 800 plus cuts. There were pieces everywhere. For your intarsia piece just re cut the piece not the project. If 2 Pieces Don't Fit In SEGMENTATION The blade is not at 90 degrees to the table or you are pushing to one side. Not sure what your car problem was but don't expect perfect cuts and relax. Slow down if you need to have fun.
Fredfret
If you let it cure for a few days the Modpodge should work ok. I almost never put a finish on picture puzzles unless they are inkjet then I seal with schellac or triple thick glaze only to keep the colors from running.
Fredfret
I cut from the most interior to the outside, tape back most of the pieces the real small pieces I skip taping. Holding down very delicate areas is normal. Those look good, keep it up.
Fred fret
First ask yourself what type projects do I see myself making? If the answer is large size clocks or furniture then the larger the better. If you plan on toy cars and trucks the 16" will work fine. MOST saws are 20 or 21" with 16 on the small side and 30" on the large side. I have a 21" and a 26" rarely exceed the size of either one but making a puzzle from a movie poster is a real challenge with the 21. Welcome to the Village please let us know what you get and some pictures are always good
Fredfret
Wichita, ks
Good job with both a new saw and spiral blades. I recommend a blade without reverse teeth. I use flying Dutchman #5 polar blades for that type project others have their favorites. Welcome to the village.
Fred fret
I am a calibration tech and have to convert from one to the other all the time. Most of the people I work with have great difficulty dividing or multiplying by 10. The metric system is a decimal system. If we all used only one or the other sure would make my life easier.
Fredfret
I use a magnifier to see the teeth. Most of the time i use my thumb nail to feel the direction of the teeth if the blade dosn't catch the teeth are going the direction of movement if it catches the teeth are going the other way. The thumb nail even works with 8/0 jewelers blades.
Fredfret
Dust mask especially with plywood and exotic woods. Safety glasses all the time (blind without) hearing protection sometimes when using the shop vac for long periods. Rubber gloves for finishing NEVER while cutting even on the table saw.
Fredfret
You do not need a special blade for plastic. I cut plexiglass and lexan frequently for templates using a FD polar #3. NOTE some plastics will melt back together and simply do not work because the heat generated by the blade. Maks sure that you cover the plastic on both sides with tape if it is missing the peeloff cover from the mfr.The sandwich idea should work as long as the blades don't get to hot. Try a small cut in a section that you don't need. The "corian" blades are nothing more than the Polar blades.
Fredfret
Any blade with reverse teeth will want to lift the project some the more reverse teeth in contact the more lift. As mentioned by others feed rate/pressure is just enough to allow the wood to move and the plade to keep up. Let the blade stay in contact with the wood but not bend enough that you can see it is bent while still cutting. It will take time to get the feel for feeding the wood into the blade. I might recomment that you use the hold down on the saw so you don't need to hold the wood down as muchas you indicate.
Fredfret
Wichita, Ks
Charles dearing did a side by side of FD and Pegas you can watch it on youtube. I dont know all the titles and stuff but it was recently. He liked the speed of the Pegas better. By the way he only uses spirals.
Fredfret
I dip then allow 15 min soak before wiping all excess off then over night dry. Poly coat if you want. I use gloss watco oil seldom poly.lacquer same as poly two coats both thin. Mineral spirit's is for thinning not a finish.
Fredfret