Cutting Out Shapes

Langadune

Langadune

Joined
Apr 19, 2012
Messages
212
I've been struggling to find the best way to cut odd shapes out of the tang. I'm trying to do something besides simple round holes with drill bits. I have a dremel but not sure what would be the best bit to use. I'm wondering if there is a coping saw blade or something like it to make such cut, or for connected one drilled out hole to another.

BTW, I'm currently using 3/16" 1095 steel.

Thanks
 
I am personally a big fan of the angle grinder. For 40 bucks of wheels and grinder you can just make the metal fly. You can totally overdo it, and you will have cleaning to do with files, but it is much faster than lots of methods. I personally like it.
 
thegeek574 said:
I am personally a big fan of the angle grinder. For 40 bucks of wheels and grinder you can just make the metal fly. You can totally overdo it, and you will have cleaning to do with files, but it is much faster than lots of methods. I personally like it.
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I have never been a fan of this method, because it makes a mess every time I do it, and my hands feel tingly for a long time afterwards.... It is quick though.
 
I think you could get just about any shapes you want with drill bits and files (or a real teeny tiny angle grinder). :)
 
I do use my angle grinder, drillbits and files to cut out the tangs on the knives I made. No problem. Even if you screw up a bit with the angle grinder, it is going to get hidden by the scales anyway. Dremmel tool is to slow to remove metal effectively. I would rather use a die grinder with a carbide bit for this matter. Also, if you have (which I presume you don't, otherwise you would not be asking these questions) a mill... well... go for it!

Mikel
 
I was afraid drill bits and files was gonna be the answer. I have a variety of files, including some jewelers files and the process has proven to be pretty slow. The shapes I'm trying to create are too small for my angle grinder. I'm talking the size of a quarter and smaller.
 
Cut off wheels on a Dremel? Follow up with some kind of grinding bit or carbide burr, then file it smooth?
 
If you have a drill press, how about a sanding drum? Drill a bunch of holes first then grind to your profile.
 
How about not worrying about the tang too much? I'm guessing you want to do something like a square pin? Drill the tang hole big enough for the odd-shape pin, and drill/file your scale material to fit the pin since its softer than steel.
 
They make a router bit and guide attachment for the dremel. Most of em come with it out of the box ;)
 
I am not sure how well it will work on 1095, but I have used a jewlers saw on 3/8" 416 SS. It is kinda slow though. You can get about any shape you want though.
 
Surprisingly to me, my Delta scroll saw cuts metal pretty well. It's really a powered jeweler's saw anyway.

It's about the only time I ever use that machine. It's just the small table top model.

I've used it to cut the tang slot through 3/4" brass.

I always thought it was one of the most useless tools I'd ever bought until I learned it would cut metal.
 
Firstly... Thanks for all the input.

What I'm trying to accomplish is a sort of lanyard loop that extends below the butt off the handle but I want it to be mostly triangular. What I've done previously was drill holes in the three corners then drill as many small holes inline between the corners then used a small file to eat away at it. It was basically a study in patience and perseverence.
 
Jeweler's Saw,it will work good for that application.Drill a 1/16" hole in each corner,insert blade through the hole and attach to saw frame and cut away.
Stan
 
grizzled, what blade do you use in your scroll saw to cut the brass with? That is a great idea.
 
SBuzek said:
Jeweler's Saw,it will work good for that application.Drill a 1/16" hole in each corner,insert blade through the hole and attach to saw frame and cut away.
Stan
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I might give this a try. I had been looking longingly at my coping saw wishing I could use it for the job. Looks like I can get the jewelers blades and frame for a pretty decent price.
 
I believe I'm using the finest tooth regular Delta blades.

I think I noticed that jeweler's blades had flat ends too, and I might be using jeweler's blades. I'm sorry, I just have all my blades in a jar, and I use the finest tooth one. There is nothing special about them.

I get about one tang hole through 3/4" brass per blade. I usually break them from pressing too hard.

I have not tried any German silver or stainless. I'm a beginner. :)
 
grizzled gizzard said:
I believe I'm using the finest tooth regular Delta blades.

I think I noticed that jeweler's blades had flat ends too, and I might be using jeweler's blades. I'm sorry, I just have all my blades in a jar, and I use the finest tooth one. There is nothing special about them.

I get about one tang hole through 3/4" brass per blade. I usually break them from pressing too hard.

I have not tried any German silver or stainless. I'm a beginner. :)
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Glad to hear this. My grandfather was a wood worker and I inherited his scroll saw. I didn't think I had any use for it except for now! I'll have to give this a go on my first ever project. I'll use the most amount of TPI on a blade that I can get my hands on. I'll be sure to use cutting oil if I can without ruining the saw.
 
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