Thursday, September 13, 2018

Hand Cut Christmas Card Scroll Saw Pattern.

Make your own hand cut Christmas cards this year. Do you need 15 Christmas cards? No problem because we are going to stack cut as many as you need. This is actually slightly different than stack cutting. I call this sandwich cutting.

We will sandwich as many sheets of cardstock as you need cards between two sheets of 1/8" Baltic birch plywood. The plywood is sacrificial and is just used to carry the cardstock

This technique works very well and leaves a nice clean cut on the cardstock. They look like they were cut with an Exacto knife. I like to use either a #2/0 or #1 blade. Anything larger tends to leave a rougher cut. Up to 10 or 15 sheets will still cut okay with a #2/0 blade. Larger stacks need the #1.

I buy the Marth Stewart cardstock from Michaels Craft store. It is very high quality.

The cards need a 4.75" X 6.5" envelope. Here is an Amazon link to a set of 50 red envelopes that will work. They are only $8 for the set. Click here for envelopes.

We are going to cut several cards at the same time.
Sandwich all the sheets of cardstock between two
sheets of 1/8” Baltic birch plywood 

The final stack needs to be 9.5” X 7”. I am running the
stack through the table saw to get it down to size.

 Cut the pattern at the dotted line to prepare it to be
glued to the stack.

 Wrap the stack in blue painters tape. Use spray adhesive
to glue the pattern to the stack.

Drill all the interior entry holes. You will need a small
bit. I used a micro bit but you can probably use a 1/16”

To get a nice clean cut in the paper I used a #2/0

It’s time to cut the pattern. There are a few small
interior cuts so take your time. Be as accurate as
you can. The paper will have some small pieces
and will be delicate until it is clued to the backer page.

 After you finish all the interior cuts it’s time to cut the
perimeter. Not the small notches ate the fold line. Use
the blade to make a small cut at the notches. This cut
will make it easier to find the fold line.

 Remove all the cards from the stack. I cut five but it
is just as easy to cut fifteen.

Use a metal rule to start the fold.

 The second page of the pattern is a template for the backerpage. Use it to cut the backer page to size.

Use stick glue to glue the backer page to the back of
the front cover of the card.