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theglasszone
2008-06-28, 1:35pm
Hi Everyone:

This information was posted in the "Tips, Techniques & Questions" section as a reply to a question on cutting sheet metal. I was asked by the author of that thread to please post it here as well, so everyone who might have similar questions could benefit - here we go!

REMINDERS & IMPORTANT NOTES:

Remember, everyone - SAFETY FIRST! I recommend any time you are cutting, sawing, grinding or sanding (no matter the material), use safety goggles or glasses to protect your precious eyesight! Also, use common sense while working with anything sharp, serrated, etc., so as not to cause unnecessary "band-aid" moments (or worse!)

TIP #1:
If you are cutting very thin sheet, use Elmer's white glue to adhere it to a very thin, flat sheet of balsa wood and allow it to dry before you cut it (available at most craft stores such as Michaels, in the "kit car" and "kite building" sections). You can transfer your "image" to either the wood or the steel (or Sterling or Brass) sheet, then cut carefully according to you pattern. This will help keep it from bowing and bending while cutting. Then just soak it in water and wash the glue off - TA DA!!!

TIP #2:
A very small "drill shot" though locations that have sharp corners in your design will help you to make clean "turns" in your cuts without stressing the saw blade. Keep in mind where the cutting pattern lines lie, and place your "drill shot" carefully on the "outside" of the corner or intersections so as not to breach your pattern. In other words, if you are cutting triangles, stars, squares, the drill holes should be just beyond the edges of the corners to allow a place for the saw blade to "turn" without snagging or putting tension on the blade.

TIP #3:
You will need to purchase a nice Jeweler's Saw and a variety of blades in various grades, depending on what you are cutting. Here's a basic eBay "search" link to help you with your purchase if you do not have a hobby store locally to purchase from. Of course, even if it's a few bucks more, I recommend buying from a Seller with EXCELLENT/100% feedback (and don't recommend Seller "Finding King" for obvious "negative" feedback reasons):

http://search.ebay.com/search/search.dll?from=R40&_trksid=m37&satitle=jeweler%27s+saw

TIP #3-A
In addition, I suggest you pick up one of these:

http://i185.photobucket.com/albums/x280/theglasszone/Misc%20Photos/SawBlock1.jpg
http://i185.photobucket.com/albums/x280/theglasszone/Misc%20Photos/SawBlock2.jpg

It allows you to clamp this V-slot block to you work table - with the "V" and hole extended outward, which gives you a work surface upon which to cut that is clear of the bench and allows you to draw the saw all the way through the work unencumbered. Here's another eBay "search" link so you can see what they go for: http://search.ebay.com/search/search.dll?from=R40&_trksid=m37&satitle=v+slot+clamp)

TIP #4 - Correctly inserting the Blade:

1. Lay your selected blade down and adjust the length of your saw so that the top and bottom clamps are about the same length as the blade:

http://i185.photobucket.com/albums/x280/theglasszone/Misc%20Photos/SawTip1.jpg

2. Pick up your blade, and with the teeth pointing DOWN and OUTWARD, loosen the bottom clamp on the saw frame, slide the blade (still with the teeth down/out) into the clamp and tighten.

http://i185.photobucket.com/albums/x280/theglasszone/Misc%20Photos/SawTip2.jpg
http://i185.photobucket.com/albums/x280/theglasszone/Misc%20Photos/SawTip3.jpg

3. While sitting, hold the saw frame as pictured in the photo below. Here you see that I have the wooden handle of the saw frame held against my body. Note that the "U" shape of the saw frame and the blade are pointing upward with the upper arm section of the "U" part of the saw frame pressing against a table or your work bench.

http://i185.photobucket.com/albums/x280/theglasszone/Misc%20Photos/SawTip4.jpg

4. At this point, position the top end of the blade into the jaws of the loosened upper clamp but do not tighten it yet. NOW apply slight pressure on the handle of the saw (leaning a bit forward with your tummy), so that the "U" bows inward just a bit (maybe a 1/8" to 1/4" or so).

5. While holding this pressure as described, tighten the upper clamp with the blade positioned in it. This allows the blade to become nice and taught once the clamp is properly tightened and the pressure on the saw frame is released! A good test is to "twang" the blade with your thumb or fingernail (gently, for heaven sakes!), and it should have a nice ring to it. This tightness of the blade helps considerably to assure a good cut and extends the life of the blade. NEVER try to cut while the blade is "slack" or not firmly tightened in both the upper and lower clamps - it will surely snap and break the blade!

Tip #5 - Cutting:

1. Since the blades are somewhat delicate, let the "teeth" do the cutting! Very slight pressure, while drawing the blade downward against the metal, will give you the cleanest cut. Use longer, smooth downward strokes, as opposed to short draws where possible. DO NOT PUT PRESSURE ON THE BLADE as you are bringing the blade back up through the metal to prepare your next downward draw.

2. Always keep the blade in an absolute vertical position; slightly angling it forward or "tilted" will often cause the blade to jam in the metal and/or break.

3. I recommend creating a "start" to your cut, using your blade held vertically and very gentle pressure, to ever-so-slightly "notch" your start point and give a good "seat" for your blade to run though.

There you go! Hope this help you all! Happy and SAFE cutting!

Hugs from CA!

Karen Hardy
2008-06-28, 1:37pm
Do I have to paint my nail tips blue too? :lol:



Great tutorial!
Bravo!!!!
Loved the tip about the gluing thin sheet to wood.
Where were you about a month ago when I really needed this info!!!

theglasszone
2008-06-28, 2:22pm
Do I have to paint my nail tips blue too? :lol:
Great tutorial!
Bravo!!!!
Loved the tip about the gluing thin sheet to wood.
Where were you about a month ago when I really needed this info!!!

Ha!!!

No - "Blue" nail tips not necessary! I change my nail tip color ever week, and dress (matching, of course) accordingly! My entire closet is in color order...90% black! All the rest is "blocks" of different colors - this week, obviously, is ocean blue...I will be wearing many of my ocean beads, with my Davy Jones' Locker ones taking center stage! :) I'm such a show-off!!!

Sorry I'm late for some of you...of course, had you asked, I would have stepped up right away. If anyone has other questions or suggestions to add to, modify or compliment/expand this tut, or any other tut needs, please just ask!

~Me

dpglassworks
2008-06-28, 2:30pm
Great Tut... I am just getting started with this so timing is perfect.....

BTW......would you do a tutorial for organizing my closet????

Chau Nguyen T
2008-06-30, 4:11pm
Great tut. Thank you very much DeAnne.
Since i started using my jewelry saw i can't put it down. Cut all of my rings with it. A lot of thanks goes to Virginia.
Please tell me where can i find that Bench File Block & Claim? I've been sweet talk my DH to make a V slot to saw my copper sheet but i haven't succeed yet.
Who could think of gluing the metal sheet to balsa wood could make the job easier and our lives happier. That's perfect.
Thanks again.
Chau.

theglasszone
2008-07-01, 1:16am
Chau~~~

Thanks so much for the nice note! I posted a general search link to find the V-slot/clamp thingie in my "Tip #3A" above. Here's the link to try - lots of choices and Sellers (but remember, I DO NOT RECOMMEND "Finding King" due to some bad experiences and negative feedback issues by myself and others here on LE):

http://search.ebay.com/v-slot-clamp_W0QQ_trksidZm37QQfromZR40

I got mine at my local bead supply store for $8.00.

One more tip if you are cutting an intricate design - draw it on a piece of paper and cut the paper out. Then glue the paper onto the sheet metal (using water soluble glue, of course!) and let dry. This give you lots of control over cutting in "lines" "swirls", etc. and the pattern is so easy to follow this way! When you're finished, soak the paper off and the metal is just perfect.

Don't forget to keep some small jewelers diamond files around - they come in handy for smoothing those tiny burrs that might be left behind.

~De in CA

Chau Nguyen T
2008-07-01, 2:44pm
Thank you for more tips DeAnne.
I haven't any bad experience with Finding King yet, i don't buy many things from them because of the big shipping.
I wandered into Rio Grande web this afternoon and found that V-clamp at $7.95 i'll order it this week end.
Thanks very much for sharing your knowledge with us. I know it takes a life time to gather this.
Chau.