Sheet metal cutting

Hello all

You have heard of writers block? Well, I think I have got modellers block as I cannot make up my mind which model to start on next. So I have been silver surfing looking for inspiration and as near as I can get I think it might be a “G” gauge garden railway next up.

I bought a job lot of large brass door finger plates some weeks back 7kilos worth and I am planning to use some of this 1.5mm thick material for frames, cab etc.

Next step – how to cut the stuff up without warping it. I had a look round at how others were managing and was quite surprised to find that many have similar difficulties. So I did it my way!

These sheets of brass are 800mm x 150mm so the method would need to accommodate this size.

These photos show how I did it.

**LINK**

The jig is simply 2 x 200mm lengths of 25mm angle iron drilled and reamed to take 2 x 5/16” sliding pins. These keep the guide faces in line. After marking the brass sheet, it is slipped between the two pieces of angle ensuring the marking line is true to the guide face. Protect the brass finish with a couple of bits of card or similar. Position the jig as shown within the vice jaws and tighten. Positioning can be a mite fiddly but would be made easier using quick release or toolmakers cramps on either end of the angle “sandwich”.

Turn hacksaw blade 45 degrees and saw the brass using the guide face to maintain a straight line.

This method gives a straight edge with zero warping and if I had had a fine tooth hacksaw blade a better edge finish could have been achieved. Although the photo does not show it this was a full 800mm length of sheet.

Much as I would love to do this sort of thing on a band saw I have no more room in my shed to fit one in – nor even for a wafer thin mint - I’m stuffed !

Regards - Mr.Creosote

AKA Stuart

Superbly simple.

Great idea. I wonder what sort of a job my plasma cutter would have made of it.

other item that might work, although I suspect still requiring some support, a jigsaw with a metal blade. That was my weapon of choice on up to 3mm steel.

Hi Stuart I have used an inverted jig saw clamped upsidedown in the vice ,Abit dodgy but it works.

I extended the table by screwing a sheet of ply onto the foot of the saw. I dont think that I would go to 800mm

A jigsaw withe the right blade would have it done in no time. I have what they call a 6X4 bandsaw but that is no use for sheet stuff ,or awkward bits, so out comes the jigsaw. I often cut up to 1/2" steel plate ( very slowly), and i recently cut a piece of 1" thick ally with it as the pics below show. It's just a question of using the right blade for the job. Cutting the plate shown took around 10 minutes. The jigsaw is a 30 year old Elu.

Cheers Derek.

Opps!!! I forgot the pics were not in my album to transfer to here, i will load them now.

Edited By magpie on 22/10/2012 17:24:00

Edited By David Clark 1 on 23/10/2012 09:47:29

Edited By David Clark 1 on 23/10/2012 09:48:07

I have cut out an intricate weathervane in galvanised 16swg steel sheet with the jigsaw. Place metal on top of some closed foam insulation sheet just thicker than the length of saw blade and cut thro metal and insulation. BUT do use goggles - a bit of brass in your eye is a hospital job.