Homebrew PCBs

DJ Delorie wrote:
>  
> 
> 
> I use an X-Acto paper cutter to cut some of my FR4, but it's difficult
> to do with the 0.8mm sheets much less 1.6. I use it on the 8 mil
> (0.2mm) and 16 mil (0.4mm) sheets only now, and use a scroll saw for
> the thicker stuff.

is it one of these ?
http://www.jerrysartarama.com/discount-art-supplies/Mat-and-Paper-Cutters/X-ACTO-Paper-Cutters.htm

Looks like they have a cutting blade fastened to a thicker steel arm. 
Are you saying you need to put excessive force to cut through 1.6mm FR4, 
causing the top and bottom blades to shift apart, especially as it gets 
close to the handle end.