[TheForge] Making dies for cutting sheet metal?

[Bruce .]

Thanks, all, for the additional responses.

While interesting, I will hold off on techniques such as laser, water jet,
and plasma cutting, because I'd rather not be shelling out money without
seeing what I can accomplish myself, first.  I don't doubt that one of
these would be excellent for a production run, but I expect to need maybe
eight of these combs.

Re, jewelry saw vs. steel.  The saw wins.  I've tried it.  I once took a
highfalutin SS compression fitting installed on a tube and sawed it
lengthwise as a demonstration to my employer how the damned things work.
It IS slow, I'll grant, so a combination of approaches may be warranted.

No vertical bandsaw available.  Too bad, because this would probably work
well.

I might try my jigsaw with a fine blade.  My saw has an orbital-path option
so that the teeth aren't engaged on the backstroke.  This could be
important if I do multiple combs simultaneously because I already know I
can't easily weld or clamp the layers together tightly enough to prevent
their vibrating.  A similar problem was the reason milling approach failed.

Now I'm considering a couple different modes of construction entirely, but
if those doesn't pan out, Inclined as follows:  Stack sheets, drill holes
for base of slots, saw either side of slot (probably with jigsaw or
abrasive disk).  Finally, finish the ends of the tines by another
technique, such as grinding or jewelers-sawing.

Speaking of jigsaws, it occurs to me I have an old scroll saw of this ilk:
http://www.woodworkingonline.com/wp-content/uploads/2007/03/Craftsman%20Jig%20Saw.jpg
that I might just be able to make operational.  If not, I have a friend who
has a couple more of these.  It seems to me one of these could be fitted up
with a jewelers saw blade ...

Bruce
NJ


On Sat, Mar 15, 2014 at 6:14 PM, jerry Frost <akfrosty at mtaonline.net> wrote:

> Must be an internet thing, it said pm on my end. Not that it matters but
> it's the sort of thing that sort of sticks on me. Oh well, guess I'll just
> have to get used to the world not being up to my expectations. <sigh>
>
> What's new?
>
> Jer
>
> -----Original Message-----
> From: theforge-bounces at mailman.qth.net
> [mailto:theforge-bounces at mailman.qth.net] On Behalf Of CGRAF
> Sent: Saturday, March 15, 2014 12:35 PM
> To: Blacksmithing List Sponsored by ABANA
> Subject: Re: [TheForge] Making dies for cutting sheet metal?
>
> It went out at 1:09AM Central daylight time.
>
> Mike Graf
>
> On 3/15/2014 12:43 PM, Jerry Frost wrote:
> > Morning Mike. I have a 10:09pm time chop on your message. Makes me
> > wonder where you're at to call it morning. Slow traffic day on the
> > information superhighway?
> >
> > Jer
> >
> > -
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