[TheForge] Making dies for cutting sheet metal?

[Rob Fertner]

Here's another way just to add to the fun. Double wide piece of steel,
plunge cut tines with a cut off wheel angle grinder, then cut piece in half
(across the tines) to get 2 combs. Clean up with a file. I suppose you can
stack multiple pieces and do this.

Rob
Wichita Ks


-----Original Message-----
From: theforge-bounces at mailman.qth.net
[mailto:theforge-bounces at mailman.qth.net] On Behalf Of Bruce .
Sent: Saturday, March 15, 2014 6:34 PM
To: Blacksmithing List Sponsored by ABANA
Subject: Re: [TheForge] Making dies for cutting sheet metal?

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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