Thanks Les
Pattern making for me is also a big chore because I do all my patterns by hand also. I convert a photo to greyscale and then ink in all the details I need by hand so sometimes the pattern making can take me almost as long as the cutting. I normally work on an A4 size sheet for the pattern and enlarge at a printing house accordingly.
Regarding the saws I use I have three in all but use two of them on a regular basis. Let me introduce you to my ladies...
The blue one was store bought and I do most of my work with this, while the yellow one is two store bought saws that were cut and welded together to give it a greater depth. At first this was a little difficult to use as was not as balanced as the store bought but managed to play around with my cutting technique and now I use it as well as the store bought one. Finally the grey one I had specially manufactured to allow me to do some really large pieces. The sizes are approx: BLUE 11 1/2 inches, YELLOW 18 inches and GREY 32 inches.
I have only used the grey one a couple of times because of a couple of drawbacks. Firstly I did not take into consideration the weight of the saw that would put a lot of pressure on my wrist but managed to overcome this problem by resting the saw on a stand to take the majority of the weight. Secondly, being so long the blade end of the saw does jump about a little and is not as rigid as I would like so it can sometimes seem to take on a life of its own. Finally and this is something I have not been able to work around yet is the reach of my arm. Seeing that my arm is beneath the wood pulling the saw down for the cut, if the blade position to the edge of the wood is longer than my arm can reach then I wouldn't be able to cut it.
Hope that this sheds some light on your questions and gives a little more insight of how I do things.
Thanks again
Tony