ATTN: stuff-making brain trust

[sistawendy]

LJ Hivemind: What tool would you use to cut a complicated shape out of a thinnish sheet of steel? Assume that there's no budget for a jigsaw. The shape's maximum linear dimension is under 2' (60 cm). Would a Dremel tool do the job?

Comments

[staxxy.livejournal.com]

it depends on how complicated you were going. a Dremel could do it with the right cutting head. Or, if the steel is thin enough, a good set of metal sheers.

[ionan.livejournal.com]

A dremel could work, but I just don't like them for anything delicate. I'd go with a jeweler's saw + blades. You could also ask Fish for help + tools.

[martygreene.livejournal.com]

This is what I was going to say as well- though it depends on how thin "thin" is in this case.

[manintheboat.livejournal.com]

Yeah, I have moderate skills and could do it with a jeweler's saw.

[randomdreams.livejournal.com]

Jeweler's saw is an awesome choice, but ya run into limitations if there are deep sections that the saw can't reach. But aside from that, it's a portable jigsaw without the weight.

[randomdreams.livejournal.com]

I'd like to see the outline.
It's hard to cut curves with a dremel, particularly inside curves. I'd use aviation snips to rough it out and maybe a dremel or a jeweler's saw to get it right to the shape you want, and then a round file to finish it off.

An idea that works well: plot your shape on a laser printer 1:1 and then rubber-cement it to the metal and use that as the cut pattern. That's how jewelers traditionally do piercing-work: it gives you great accuracy and cleans up beautifully.

[randomdreams.livejournal.com]

To expand: dremels have a strong tendency to wander because they twist during use since the bit is spinning. I've found it's best to cut more or less to shape, and then work my way up to the cut line using the dremel perpendicular to the cut, the way you'd use a file, rather than trying to cut parallel to the line or actually cut the line with the dremel. It's a lot more controllable.

[neuro42.livejournal.com]

Me, I'd send it to the waterjet place on Vashon, or have a friend plasma cut it, or it might fit in the laser cutter at Metrix. But a jeweler's saw will work. Eventually.

[randomdreams.livejournal.com]

bigbluesaw.com did pretty well for me: quick service and cheap, but I got a one-time bargain.

[ladyallyn.livejournal.com]

Laser etch the pattern as guide to keep dremel/jewelers say from wandering? The print and glue works very well and we /do/ know people with plasma cutters... though I'm not sure of availability.

[dianala.livejournal.com]

If it is thin enough an aluminum, you can use a die-cut machine like they have at craft stores (ie Ben Franklin). But that assumes a shape that they have a die for. What shape is it?

[sistawendy.livejournal.com]

What shape is it?

It's a surprise. Let's just say it has lots of curves and some voids.

[dianala.livejournal.com]

Well, let's just say, can it be cut out of very thin aluminum sheeting? If so I may be able to help you.