Thread: Cutting plexiglass w/o bandsaw?

Update: here is my first rough cut out.
Thanks for the help gentlemen. We are making progress!!!
Keep it coming.

Thanks,
D

How am I doing?

you need to match the scales together to shape them identically and drill the holes

If you drill the pin holes first you have parallel surfaces which helps it stay square when you pin it and you dont end up with as many off centre problems
I use 2 face tape to stick them together, drll and then shape

Mike

I use a coping saw, I then sandwich the two pieces together with double sided tape, then cut out the scales roughly but still quite accurate then mark the pivot and wedge holes drill them out, the shape them as a perfect pair of scales, including polishing them, then I drop them in warm water then gently part the scales because double sided tape can be quite difficult to remove.

Jamie.

If you own a belt sander you can flip the sander upside down, put it in a vice and lock the trigger on. Then shape them to your line this way. You can use the nose, where the front roller is, to shape the concave part of the scales. Use the middle, where its flat, to shape the convex part of the scales. This is how I do all my scales. Use a 120 belt so the hand sanding afterwards goes quicker. Its all you need in grit anyways seeings how the belt sanding removes a lot of material very quickly. Then hand sand going through your progressive grits. I find this to be a very quick method that works very well.

Yep.....What HARRYWALLY said !

Mike

HARRYWALLY,
Thanks but unfortunately I am doing it the hard way. C clamps hand file and sandpaper. One day i'll have the "goods" for working on my projects.
Let the long laborious journey begin!

I use one of these. At least similar!

Using a Bench Pin With a Jeweller's Saw

Coping saw for the rough cut, sander for the rough shape, then hand sanding the rest of the way. I use a dremel drum sander bit for any concave or convex surfaces b/c it's just a pain to get the angle just right on that belt. Oh, and don't forget to round your corners too, just sand up and over the edge; works great without flattening the very top of the lines. I just finished a brass and orange g10 lined wedge by hand...let me tell you it was a biiiiiioooooooooooooootch! God I can't wait to get a scroll saw!