How do you cut the slot in the front of the plugs as I have only a scroll saw and when I follow the line on top the blade wanders all over on the underside. I am thinking of making a metal jig and using a coping saw and just put the jig in the vice. went to Ace hardware looking for a wider scroll saw blade but all seem to be the same size.
Don't want to have to shell out for a band saw as there has to be a better way, without spending mega bucks.
Nip

Should have been Cutting

use an exacto miter blade works fine

Japenese-style pull saw.

On the lines of the Japanese saw , but without the big bucks, put you blade in a regular hack saw so it cuts on the pull. Go slowly, use your thumb as a guide. Use a not too fine tooth blade. 32 per inch is way too fine. Maybe 18 to 24.

band saw

Where do you purchase the Japenese pull saw--Hobby shop?

Amazon.com, rockler.com

Hack Saw works good

it depends on the thickness of the lip, for the thin ones, I use a coping saw, for the thicker ones I use a back saw...Both can be purchased at Home depot or Lowes.

I second the hacksaw.

I use one of those Japanese pull saws if I don't use the bandsaw

You could be feeding too fast, have a dull blade or not enough blade tension. Don't give up yet..

you could also use a dovetail saw found at about any hardware store or home depot. the better ones have a reversable blade so you can cut on the push or pull stroke. Irwin makes a decent one.