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Spend your $$$ on a jewlers saw and a gross of blades and learn how to use it...you will be able to make any guard you want.
Mace
Spend your $$$ on a jewlers saw and a gross of blades and learn how to use it...you will be able to make any guard you want.
Mace
I use 2/0 blades for my guards they work well for the material i use which is for the most part brass and wrought iron. Just remember to saw smaller than you need and file for a snug fit.
Bob
Do you mean cast brass or bronze? Sure.
As for sizes the larger the number the larger the blade. I kind of think of zero as the midpoint on the scale. Blades get smaller by "oughts" (2/0, 3/0, 4/0) and larger by integers (1, 2, 3...). I would probably use a 2 or 3 with .25" thick material. You might want to pick up a few sizes and try them out and see what works for you. Maybe something like: 2, 0, 2/0. They come by the dozen or the gross. Use a little wax or cutting lube to help cut your way though your stock. Go slow, keep your blade vertical and taut in the frame with the teeth pointing down and you'll do fine. Be prepared to snap blades for a while until you get the hang of it. Here's a link that might help.
http://jewelrymaking.about.com/od/easyfabricationprojects/a/082606.htm