Saturday, November 17, 2018

Cupid Wedding Cake Topper Scroll Saw Pattern. Cutting 1/4" Thick Aluminum.

A couple of years ago I was contacted by a small company who wanted designs for wedding cake toppers. I worked on a few but never made a deal so they have just set in a folder. I actually had forgotten about them until I was cleaning out old folders and found them. I decided I might as well post them. 

I know there are not too many wedding this time of year but if you have one in the future it will be in my catalog when you need it. 

Personalized Christmas Ornament Pattern Orders:

I did not stay caught up for very long. I am a little backed up right now but I will work on getting caught back up later today. If you are waiting for an order look for them in your email later tonight. Thanks for your patience.

Cutting 1/4" Thick Aluminum Flat Sheet with the Scroll Saw:

Is it possible and would you want to?

If you attempt this technique please wear safety glasses. The shaving are tiny and you do not want them in your eyes.

This is a simple ring I cut tonight from 1/4" thick aluminum sheet. That answers the first question. Yes, it is possible to cut 1/4" thick aluminum. You may also notice that it has a pretty good finish right off the saw. 
I used Mother's Aluminum buffing compound to give it a bright sheen. With a bit more buffing I could get rid of most of the small scratches but it looks pretty good. 
I have very little knowledge of jewelry but I assume using aluminum for jewelry would require some type of coating to prevent it from reacting with your skin.  This was just an experiment. I will do more research as time permits.
To make this cut I used a Pegas #1 Metal Cutting blade from Bear Woods. I did not have a #3 or #5 or I probably would have tried those first. I suspect the finish would have been a little worse with the larger blades but it also would have been easier to cut.
 I bought the Aluminum stock from Amazon. You can find what I bought at this link. I noticed that it went unavailable after my order. I don't know when they will restock it. I'm sure you can find it locally if you search. It took about 8 days for the order to be delivered.

 I had not cut aluminum this thick before so it took me a few minutes and blades to figure out the best strategy. Feed rate and saw speed are critical when cutting this material. I started out way too fast with both. I got the best results when I turned the saw down to about 1/3 full speed. That is very slow.

Feed rate is even more critical than saw speed here. You absolutely have to let the blade make the cut. If you push it any at all the blade and aluminum heats up and the blade breaks. I went through four blades cutting out the small square. Once I slowed way down I completed the rest of the cut with two blades. 
I experimented cutting dry and with oil. Dry worked better. It appeared that the oil caused the shavings to stick to the blade and make it feel dull. When I cut dry the shaving fell away and the blade cut better. You do need to have a piece of wood under the aluminum or it will scratch the table. The aluminum is so heavy that I just laid it on a piece of 1/8" BB ply when cutting out the small blank.
When I started cutting the ring from the small blank I taped the aluminum to the board. To make a ring you need to be very accurate. A ring needs to be round. 

Now let me answer the second part of the question I asked at the top. Would you want to cut 1/4" thick aluminum? It's a challenge but it's something different that you may not have tried before. I would not attempt anything too large. It just takes too long to cut.  

I think small pieces of jewelry or other small items might be worth the time.

If you are interested in trying to cut a ring you can visit my catalog and type "rings". You will find a pattern that has all the different sizes for ring patterns.

Here is the link to my catalog ...

Bear Woods Sponsored Giveaway:

Entries are going strong for the Bear Woods Giveaway. We have over 3,000 entries with 16 days left to enter. If you have not entered yet them click the link below and maybe you will be the winner.

The 1st Winner will receive a $100 Bear Woods gift certificate.
The 2nd winner will receive a completed Charles Dearing artwork.

$12 per sheet of 12 coins plus $3.50 shipping
Inlay with a 1" Forstner Bit.
The perfect way to sign your work.

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Email Newsletter Readers: Remember that the Newsletter is just a copy of the daily blog post. To see the post in it's proper formatting click this link. If you ever misplace a pattern or any item you see here you can always find it on the blog. Everything stays on the blog forever. 

Products for your consideration:

Scroll Saw Pattern Design Tutorial: DVD
Let me teach you to create a beautiful wooden portrait pattern. I will show you everything you need from start to finish. The video will show you the free software program you can download for Windows or Mac OS. I will show you how to install the program and configure it for best results. 
Then I will show you the technique to take your photograph and make a pattern from it. When the pattern is complete we will go in the shop and cut it.
The DVD is $10 plus shipping. This is a data DVD that you will use on your computer to watch the video tutorial  

Every Scrollsaw Workshop Pattern from 2007-2017 in DVD
Purchase the entire Scrollsaw Workshop pattern catalog for offline access.

This DVD has 2,300 patterns published from 2007 thru 2017.
The DVD is $20 plus shipping. Ships to 60 countries around the world.

If you use the DVD on a Windows PC there is a simple viewer program to browse through the patterns.

The DVD also works fine on a MAC. The viewer program is not MAC compatible but there is an included PDF with all the patterns shown as thumbnails for easy viewing. 

Unique Wooden Vases:
Want to create beautiful wooden vases on the scroll saw?
My two "Wooden Vases on the Scroll Saw" books make it easy.

The books are $12 each and available for instant download after purchase. Click for Video Demonstration.

The Scrollsaw Workshop is primarily supported by donations. If you enjoy this Blog and would like to make a donation please click this Button. Your support is greatly appreciated.

My Sponsors:
Support the businesses who support our community.
Home of Pegas scroll saw blades.

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This is the end of the daily posts. Keep scrolling for lot's more scrolls saw fun!
Bear Woods has been around since 1987 serving our hobby. They offer a wide range of craft products including Pegas scroll saw blades, clock inserts, toy parts, workshop supplies and much more. In my ten years of writing the Scrollsaw Workshop blog I have never received a complaint about Bear Woods. I get thousands of email a month so that's saying something about their customer service and quality products. Please support the people who support our hobby. Click now and visit Bear Woods.

Heritage Wood Specialties. Scroll saw ready boards!

Heritage Wood Specialties is a nationally recognized supplier of superior quality hardwoods to fine woodworkers across the US and Canada. Novice hobbyists and experienced enthusiasts alike can enjoy the high quality woodworking materials and kits available from Heritage Wood Specialties. Great source for scroll saw ready boards.

Seyco began business in 1986 with the goal to supply the best customer support and quality products in the scroll saw industry. I have worked with Seyco on many occasions and I can tell you they are simply the best. Please do yourself a favor and click the image above. Steve Good

Free Pattern Catalog. 1000's of free patterns.

Thousands of FREE scroll saw patterns. No registration or signup required.

The projects form these patterns can be sold without restrictions. The patterns cannot be sold.

Click here for the Free Online Catalog.


Wooden Vases on the Scroll Saw Book $12 Each
Each digital book is available for download immediately after payment.
The books are $12 per edition and contains eight unique patterns each.
Watch the following video to see how easy these beautiful scroll saw vases
are to make. 

Order the $3 pdf Catalog

This is a PDF of all the patterns in my free catalog. It is for Windows only and has a program to automatically download the pattern to your computer. Please watch the video below before you order. Click the picture to order.
You do not need a PayPal account to order. At the bottom of the PayPal page is a button that will allow you to pay with a credit card. After successful payment click the Return to Merchant button for the download.

Stencil Printer 1.7

Stencil Printer Instruction Video.

The Scrollsaw Workshop Stencil Printer 1.7 is my latest software for creating patterns. It will create key chain fobs, desk name plates and more. Click the image above to download the latest version. It is free to use donationware. This software is for Windows PC only.

Scroll Saw Pattern Printer update 1.1

Scroll Saw Pattern Printer update 1.1
Download the Free Scroll Saw Pattern Printer Version 1.1. Create name patterns in seconds. Windows PC only.
Download Version 1.1
Please consider a $5 donation for The Scroll Saw Pattern Printer v1.1.

Scroll Saw Keychain Pattern Maker

Use the Scroll Saw Keychain Maker to start a small keychain business. Build yourself a nice display and make up severl keychains with common names. Sell at craft shows, on Ebay or at work. Everyone needs a keychain. Take custom orders. Heck just make them and give them away as gifts. It's all made easy with the Scroll Saw Keychain Maker. Watch the video demonstration then download the file below and get started with the fun.
The following link will start the download process. After the file download is complete just click the setup file and the program will be installed. Please consider a $5 donation for the program.

Download the Oval Keychain Pattern Maker.

Enjoy designing and printing these great personalized key chains. Give them as gifts, make them for fun or sell them at craft shows. It's easy, just watch the video demo then download and install the program. You will be designing these fun projects in minutes. Windows PC only.
Download the Free Oval Key Chain Pattern Maker. Create Oval key chain patterns in seconds.
Download Version .9a
Please consider a $5 donation for The Oval Key Chain Pattern Maker.

T-Shirts and More.

T-Shirts and More.
Show your love for the hobby and support the Scrollsaw Workshop. Safe and secure order fullfilled by CafePress. Take a look. You are sure to find something you like. CLICK THE IMAGE to visit the store.

The Lifter

Papa's Custom Patterns.

Philip Lowndes Noah's Arc Pattern Available. Watch the video below.

This video is from Philip Lowndes. He is the designer of this beautiful Noah's Arc puzzle pattern. If you would like the pattern follow the link below.
Buy This Wonderful Heirloom Puzzle Pattern

Think Safety

Remember to keep the safety of yourself and others in your work shop in your thoughts at all times. Always wear eye and ear protection. Follow all the manufactures warnings that came with your power tools. If I demonstrate something on this web site that you don't feel is safe, don't do it. Your safety is your responsibility. Fingers are handy things, try to keep all of them.
The Scrollsaw Workshop Blog is in no way affiliated with or sponsored by Scroll Saw Woodworking and Crafts Magazine formerly (Scroll Saw Workshop Magazine) or it's publisher Fox Chapel Publishing.

Scroll Saw Woodworking and Crafts