[TheForge] Making dies for cutting sheet metal?

[jerry Frost]

Bruce if you can't weld a stack you won't be able to use an abrasive saw,
the chatter will destroy the disk very quickly. It's the same action as
makes a grinding wheel dressing tool work. 

The old scroll saw will probably work fine but you'll need to slow it down,
new pullies.

Rob has a good idea but you still can't stack blanks and use a cut off disk,
it'll just eat disks.

Jer

-----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 3:34 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