[TheForge] brainstorming and other thoughts on cutting sheet metal

[terry l. ridder]

hello bob;

thank you for the carriage bolt & plywood suggestion.

jerry's rose kits are made from 18 gauge black sheet metal.
i personally do not like the pattern design of the petal disks that
jerry uses. i also want some 'difference' between the petal disks.
laser cut petal disks, in my opinion, start to make the forged rose
a 'commodity' item not an individually crafted item. again, the above
are my opinions.

24 gauge black sheet metal is 1lb per square foot.
18 gauge black sheet metal is 2lbs per square foot.
therefore, 18 gauge should be twice the thickness of 24 gauge black
sheet metal.

one comment i have received concerning the forged roses is how heavy
they are. i used 24 gauge black sheet metal.

there are two ways to decrease the weight of the forged roses.
0. use higher gauge black sheet metal.
   25 gauge sheet metal is 14 oz. per sq. ft.
   26 gauge sheet metal is 12 oz. per sq. ft.
   27 gauge sheet metal is 11 oz. per sq. ft.
   28 gauge sheet metal is 10 oz. per sq. ft.
   29 gauge sheet metal is  9 oz. per sq. ft.
   30 gauge sheet metal is  8 oz. per sq. ft.
1. make the forged rose smaller.
   i have made three petal pattern sizes.
   large, medium, and small.
   medium is    half scale of the large.
    small is quarter scale of the large.
    large uses a 1/4  inch round stem.
   medium uses a 3/16 inch round stem.
    small uses a 1/8  inch round stem.

solution 0 is doable with the provision that higher gauge black sheet
metal is a special order in my location with in my opinion excessive
minimum order rules. 30 gauge would probably be the highest gauge that
would be useable.

solution 1 is easier except there is a limit as to how small a forged
rose may be. the quarter scale pattern would appear to be the limit for
my ability to still be able to work it since the fine motor control of
the left hand and arm is gone.

combining the two solutions would be beneficial.

On Tue, 31 Dec 2002, Bob Bergman wrote:

bob> 
bob> Jerry Kirkpatrick sells rose kits, 20 ga. material.
bob>  For stack sawing- Bolt the blanks to a piece of plywood with a cariage
bob> head bolt . The head of the bolt will pull in to the plywood and you can
bob> gang cut on a band saw. Drill holes at the bottom of the pedals so there
bob> is a rounded area there which helps keep tears from occurring when you
bob> bend them up. Bob
bob> 

-- 
Terry L. Ridder ><>