PB tools?

[kaintuck]

I wonder if i need to 'up-grade' my cutting tools~been thinking of getting a bandsaw, or a jig saw, and maybe a better coping saw~ Otto-Frei has nice ones...

What do YOU use in cutting your Patch Boxes out with?

marc

[KLMoors]

I use forstner bits and chisels to cut out patch boxes. I don't have a bandsaw, but I do have a nice Bosch jigsaw, and I have come up with lots of ways to use it for the things I would do with a bandsaw. I cut out my blanks with it and I cut my butt plate shapes with it.

I have a small shop and, although I would love to have a bandsaw, I can't really see it fitting anywhere. So, I have made do with the jig saw.

[smylee grouch]

I have used a jewlers saw and it worked OK.

[alyce-james]

Good evening Marc; I also use a Jewelers saw with bee's wax, cuts like butter. Have a great week end. AJ.

[Acer Saccharum]

I use a jeweler's saw in combination with a jeweler's pin, which is naught more than a piece of wood with a slot for the blade. It supports the metal while you're pulling downward with the saw. Always set up the saw to cut on the pull stroke. This vertical arrangement keeps the weight of the saw frame from breaking the blade.

[kaintuck]

Thanks fellas, I just ordered a new saw frame and some #1 and #3 blades....

Now if I can just work slow and patient!

[Mark Elliott]

Only use the good ole jewelers saw.   I tried a table type jig saw a couple of times.   It just runs too fast and breaks a lot of blades.   You can cut pretty fast with a jewelers saw and good blades.  Make sure you use blades intended for steel.   Softer blades will wear out quickly even in brass or silver.  I use Swiss/German blades.  The main thing about using a jewelers saw is to move the blade forward some as you pull it down and feel your way through the work.   You speed up and slow down and turn based on feel.  A jig saw just doesn't have any feel.    Just keep it simple.   A drill press and bandsaw can be real useful in gun building, but not much in the way of other power tools.   A metal lathe is good for making parts and tools.  However, you can get by without any power tools.    Resist the temptation to buy expensive power tools.  Your money is better spent on good quality used hand tools.   As long as you learn to properly sharpen your hand tools,  you will not regret buying the hand tools.  

As to sharpening,  you can buy lots of stones and sharpening devices.  I have gotten the best results out of DMT DiaSharpe diamond hones.   I have two 2"x6" stones.   One has a course grit on one side and an extra course grit on the other side to use for reshaping edges.   The other stone has a fine side and an extra fine side that is used for routine sharpening and honing.   Glue a 4" x12" piece of thick leather to a wood board for use as a sharpening strop.   Use Simichrome polish on the leather.   As I said, you could spend more, and I have, but you won't get a better result.      

[KLMoors]

Now I understand why I was thinking "How could anybody ever use a bandsaw to cut out a patchbox?"  I thought you meant cutting the box hole, not the brass!  Doh!

I use a coping saw with Robert Larsen blades that are meant for cutting metal. These are about ten times tougher than jewelers saw blades and they last forever.  They will not cut as tight a radius as jewelers saw blades, but pretty close. I still use the jewelers saw some, but 90% is done with the coping saw.

[kaintuck]

DANG IT!!!
Now I have been to the rlarson.com/catalog/RLC_Catalog.pdf‎ web site...ANOTHER place to buy tools from!

you guys are get me divorced~!

[2veeps]

Having just cut my first patch box, I second the bees wax. Went through 4 blades to cut 1 inch before I lubed the blade and finished the entire patchbox with the same blade.

[kaintuck]

I guess the wax helps the blade Bzzzzzzz thru the metal
Marc

[smylee grouch]

Yes and you have to bee carefull when using them. 

[Acer Saccharum]

I have tried holding onto really tiny parts with my fingers when sawing them*.

* what do I mean by 'them'? Sawing little parts or fingers?

If you try sawing your fingers, you will experience pain like no other. A knife, when sharp, is relatively painless when it slices into your finger. A jeweler's saw blade finger cut, however, is a most excruciating experience. Not only do all those little hooks tear your flesh and shred all the nerves in the immediate area, but the nasty little teeth fill the cut with whatever material you happen to be sawing.

[KentSmith]

too much information. LOL

[Acer Saccharum]

I know. 

The other bad thing with these great little saws is if you bust a blade on the downstroke, and plunge the broken stub, still held very firmly in the frame, right into one of your clamping fingers. It hurts extra bad, because you're holding the work down real hard, then you jam a little pin of a blade into your finger. When you release the pressure on your fingers, the blood just SHOOTS out of the little hole you just made.

[mountainman70]

kinda like sticking your finger into a hampster cage.Tom,vhat type Blood do you have?bwahaaaaaaaaaaaaaaaaa!!!

[DaveP (UK)]

I used to love to take a deep breath, sit down, and calmly and steadily make an intricate cut with my jewellers saw. I found it very important to be physically and mentally relaxed in order to avoid breaking blade after blade.

I'm going to have to find another way now, 'cos relaxed just isn't going to happen 

[bama]

I struggled with using a jewelers saw for a long time until I learned a few tricks.

First, make sure the blade is installed to cut on the down stroke as has been mentioned.

Second, make sure the blade is tensioned correctly. You have to compress the jaws of the saw slightly as you tighen so that after tightning the blade sounds kinda like a banjo string if you pluck it.

Third, use bee's wax as lub for the blade.

After learning to do these things I can now cut out a patch box and only use a couple of blades.

The numbering system is confusing for blade sizes. I think the rule of thumb is to try to have a minimum of two teeth per material thickness. I have found that a size 2 seems to work well for me. I should say that I seem to break fewer of these.

[Thom]

What Bama said.
It took me a while to learn how to use the jewlers saw, now it is a pleasure to use.
I think the blades I use the most are 56 tpi

Thom

[T*O*F]

It supports the metal while you're pulling downward with the saw.

With my old saw, I always pulled the handle off on the downstroke.  Instead of stopping and epoxying on then and there, I kept at it swearing to do it when I finished the piece.  Needless to say, that was years ago and it still ain't glued.

Instead, I bought a Knew Concepts saw and don't worry about the old one anymore.