@ brendeg, I agree with Roger. Sounds like you are using a cheap grade of plywood like Luan that is used for door skins, cabinet backings and a floor under lament. You won't have that problem with Baltic Birch Plywood. BB is a very nice wood for the scroll saw. It is a very strong plywood even after cutting your fretwork. All plies are birch. Inner plies are virtually void free. Edges finish very nicely. I get mine from
Sloans Woodshop Great products and great service.
