Scroll saw

DR.BOOM

DR.BOOM

Joined
Jan 2, 2011
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255
Can it be used to cut out blades, anybody do this or is it just left to the bandsaws?
If it does work what kind of blade should I use to cut them out? I usually cut knives out with a plasma cutter but we are relocating and I will be separated from it.
 
Get a bandsaw with a variable speed motor. I use the Harbor Freight portable that I picked up on sale for $70 last year. Works great. Be sure to get the bi-metallic bands with at least 14 TPI. They sell a pack of 3 Morse brand bands for $20. They work well for me and I've only busted one since I started using them... wore another one out, but it was still intact.
 
Scroll saw blades are too thin and weak for metal. I use a portable bandsaw but have used a jigsaw with a metal blade in the past... slow and steady.
 
I relied on my angle grinder before I got my bandsaw. The Angle Grinder is a very useful tool in knifemaking!
 
I will agree with the angle grinder. you can buy one cutting disk and one grinding disk and be fine for several knives. use the cutting disk for most of the heavy work and then finish with the disk.
 
I was just about to ask how you guys use an angle grinder to cut it out. To me it just seemed too easy to make a mistake. Then again a Plasma cutter is probably the worst looking cut possible without training. What size angle grinder is recommended for this?
 
Basic 4.5 inch. Just don't try to steer it. Make lots of relief cuts and do final shaping on your grinder.
 
I've used a portable jig saw to cut some 01 steel (1/16", 3/32" and 1/8" thick). It didn't work as well as I hoped, the difficulty was clamping and supporting the stock properly. For me it is just as fast as using the drill and hacksaw method to cut my blanks. Might work ok if you clamp the stock to a sacrificial board for support and rigidity, but knowing me, I'm probably go too fast and get the metal all nice and hot and set the board on fire.

Haven't tried the Sawzall with a demolition blade yet.

Ric
 
Personally, I wouldn't go with the angle grinder. There are serious hazards with that approach, especially if you aren't properly protected. I started off using that method, then switched to the band saw as soon as HF had a sale (plus my 20% off coupon). It's a FAR better approach than reciprocating saws or scroll saws. It's also cheaper than a visit to the emergency room.
 
There are serious hazards to all espects of knifemaking. You should be properly protected any time you work with power tools.
 
jawilder said:
There are serious hazards to all espects of knifemaking. You should be properly protected any time you work with power tools.
Click to expand...

That's true, but the risks grow when you start using tools for things they weren't designed to do.
 
I guess I don't understand what you mean. What is wrong with using a cutoff wheel to rough cut a profile then the grinding wheel to finish the profile?

I'm not suggesting that you cut a radius with a cutoff whell or put any lateral stress on it. So what do you have in mind that the angle grinder isn't designed to do?
 
I've gotten an angle grinder to cut out blanks.
(after using only a hacksaw and later a dremel)
It works good. But also I've surprised myself how often I've used it for other non knife related tasks as well.
It will even cut stone with a diamond disk. I find it to be a handy all round tool.
 
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jawilder said:
I guess I don't understand what you mean. What is wrong with using a cutoff wheel to rough cut a profile then the grinding wheel to finish the profile?

I'm not suggesting that you cut a radius with a cutoff whell or put any lateral stress on it. So what do you have in mind that the angle grinder isn't designed to do?
Click to expand...

There was a thread that discussed this some time ago (months ago). The problems come in a number of places. First, the cut off wheel can break and fly loose, lodging in the first soft thing it finds (human flesh, for example). Second, many people use the tool without the proper guard installed, increasing their risk. Third, when you're trying to cut curves, you may be putting stress on the brittle cut off wheel that causes it to break. And these are just the things I can think of, and I'm an idiot. Someone smart could probably name a dozen more reasons not to use this tool for this job. I know they did in a previous thread.
 
Your second and third points are mute because you should keep the guard on and you don't cut curves with it. You cut in straight lines. The first part is true, but that also applies to band saw blades. You minimize that from happening by not doing the second and third thing you mentioned. Diamond cut-off wheels were design to cut off metal, so I don't know why you say it is not designed to do that.
 
You can cut curves with a angle grinder, but only easy curves.
I use thing cut off blades and when they are half way worn down the radius is small enough to cut curves.
If you go over the curve in many passes and have an opening on both sides you'll be able to pull it off
 
I gotta say cutting with the angle grinder just sucks. Too bad you are losing the plasma. You sure you can't do something to take it with you? Anyway, the portaband saws are really good for doing what you are doing and if you plan on doing this a lot, think about getting blanks cut with water or laser. There be my $.02 worth.
-M
 
Jig Saw, Scroll saw, are not worth using. they even have a hard time with some G10 and Micarta. I have a friend that was using an angle grinder to cut some mild steel for a frame on a Landcruiser (He was not using it improperly, and guard was in place) the wheel broke apart and a piece embedded in his bicep. Band saw is the way to go...
 
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