Die Filer

[scrdmgl]

For sometime I've been considering the construction of a Die Filer and was aware of the kits offered for finishing and assembly. As an alternative, I decided to search for an existing piece of equipment that met the necessary alternate movement to accomplish the function. I felt that a Scroll Saw for plain blades, would fit the bill and bought a second hand never used 16" Delta cast iron model for the purpose. The actual file used in the conversion was a section of a 3/8" wide x 3" long flat mini file bonded to a piece of CRS stock 3/8" wide x 6" long to correspond with the dimensions of the blades used in the saw. Both ends of the file backing were drilled for a 5 mm Allen screw to attach to the arms and the polished surface of the bar roughed up by using the method indicated in a recent article in this blog, to make possible the bonding of the epoxy cement to both pieces. The file itself needing no preparation given its toothed surface. After 24 hrs. curing period the parts were solidly glued together. I ordered a single wheel knurl holder for this purpose which I feel will do an even better job of providing a good surface for the epoxy to fill and stick.
I will report on this issue when completed.
To allow side cutting on one side only, I allowed one edge of the file to slightly protrude out of the bar on one side and belt sanded the other side smooth to prevent cutting against a shoulder if needed.
If required, the table can be tilted up to 45 degrees and a built-in air bellows, provides air to blow the filings away from the table during operation. No bad, no bad at all. Running of the machine appears to be a little frantic, but having no experience with neither scroll saws or die filers I figure that is normal and should not affect the operation or life of the file section which can always be replaced easily and cheaply.
It should be noted, that the contraption intended use is for finishing and slight removal of stock;other means for material removal should be used prior to the use of the filer. This saw is single speed only.


Normal or regular use of the saw only requires changing the file by a saw blade in the usual manner.
Mission accomplished I say.

Since the post was originally presented in these pages, some improvements and changes to the original design, have taken place.
First of all the use of a backing plate is completely unnecessary, since the length of the flat part of the files used, allows direct clamping by 4mm Allen socket screws to the working arms of the saw. Simply drill the file at both ends with a 4mm carbide drill. Second, the saw itself can be converted to direct metal cutting, by replacing the tiny scroll saw blades, with Bosch Swiss made metal cutting jig saw blades. Those blades work at regular jig saw speed, will go through anything and last a long time at their job.
Using any other brand is useless when compared to the quality of those blades. They are available at Home Depot, Ebay or anywhere else. The saw blades can be attached in the same manner as the files. There you have it, a filing machine with a generous size tilting table, and a metal cutting saw for many small or medium sized pieces of any metal. See picture of tap drilled with carbide bit.