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Thread: saber saw keyway cutting

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  1. #1
    Supporting Member mwmkravchenko's Avatar
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    This I have done. Necessity makes for ingenuity.

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    nova_robotics's Tools
    I don't have a shaper and may have to steal this at some point. Well done, sir.

  3. #3
    Supporting Member Frank S's Avatar
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    Quote Originally Posted by nova_robotics View Post
    I don't have a shaper and may have to steal this at some point. Well done, sir.
    My dewalt saber saw is variable speed so I could go as slow as I felt necessary. Holding the small sprocket by hand can get dicey fast so if you use this idea I recommend a plate with a slot in it so the part you are cutting has a full bearing surface to rest on.
    be safe
    Never try to tell me it can't be done
    When I have to paint I use KBS products

  4. The Following 5 Users Say Thank You to Frank S For This Useful Post:

    baja (Jun 15, 2023), nova_robotics (Oct 21, 2021), Scotty1 (Jun 11, 2023), that_other_guy (Oct 22, 2021), Toolmaker51 (Oct 24, 2021)

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    Supporting Member Toolmaker51's Avatar
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    Quote Originally Posted by Frank S View Post
    My dewalt saber saw is variable speed so I could go as slow as I felt necessary. Holding the small sprocket by hand can get dicey fast so if you use this idea I recommend a plate with a slot in it so the part you are cutting has a full bearing surface to rest on.
    be safe
    A small 'throat plate' opening is important regarding vertical action tools such as die filers and bandsaws. If you can hold part down, all goes well; and cut surprisingly close patterns.
    The reciprocal cut of die filer is aided with a hold-down; an overarm maintaining light contact with part. Some use a spring and roller, others a finger or ski shaped leaf spring bearing down with light pressure, while you maintain the feed rate.
    Sincerely,
    Toolmaker51
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    Supporting Member Christophe Mineau's Avatar
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    Christophe Mineau's Tools
    Could be fun if you could also adapt a needle file to fit the sabre saw jaws, maybe with some kind of support at the other end...
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  7. #6
    Supporting Member mklotz's Avatar
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    Quote Originally Posted by Christophe Mineau View Post
    Could be fun if you could also adapt a needle file to fit the sabre saw jaws, maybe with some kind of support at the other end...
    Jigsaw blades cut on the pull stroke while needle files cut on the push stroke. This means that needle files must be mounted upside down in the jigsaw. You can see at least one way of doing it in my miniature die filer article...

    Miniature die filer
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  8. The Following 2 Users Say Thank You to mklotz For This Useful Post:

    Christophe Mineau (Oct 25, 2021), Frank S (Oct 22, 2021)

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    Frank, Nicely done! Yes, I agree necessity does have a way of making us think outside of the box sometimes. Well done.

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    Clever but wondering if you also mount more than one blade in the jigsaw to increase the cutting width..?

  11. #9
    Supporting Member Frank S's Avatar
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    Quote Originally Posted by ansteesolutions View Post
    Clever but wondering if you also mount more than one blade in the jigsaw to increase the cutting width..?
    My Dewalt has a collet type blade lock that will only open wide enough to accept a single blade other brands may have a different means of securing the blades.
    I found that making 2 cuts at just under the finished keyway width then slicing out the remainder from between them worked very well. then I finished the keyway with a small file. I always try to make my keyways as near to dimensionally true as possible.
    Even when I has a broaching machine I would finish the cuts with a file. I have made a statement before about files. I love them and they hate me. New files get treated like precision instruments old dull files become scrapers or knives I can mill a head or deck an engine block and set the fit of a V8 intake manifold with a large file to almost the same precision as a CNC mill or surface grinder it just takes me a while longer.
    Never try to tell me it can't be done
    When I have to paint I use KBS products

  12. The Following User Says Thank You to Frank S For This Useful Post:

    mwmkravchenko (Oct 26, 2021)

  13. #10
    Jon
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    Congratulations Frank S - your Keyway Cutting Tool is the Homemade Tool of the Week!

    A big week, but this is a clever solution with an excellent result.

    Some more good builds from this week:

    Chain Link Fence Tool by Mr.DK DIY
    Shaper by Frank S
    Welder's Helping Hand by orioncons36
    Lathe Follower Rest by bouboulas
    Hot Bluing Method by engineer steve
    Rotary Tool by fox craft
    Plastic Chrome Plating Method by Kovanca Polock
    Keyway Slotting Setup by mariost
    Bandsaw Fence by e_m_maker
    Lucas Magneto Test Rig by Mr. Factotum's Workshop
    Log Splitter by warsztatOdZera
    Clevis Pins by Frank S
    Die Holder by liberal
    Marking Gauge by liberal
    Lathe Riser Blocks by Frank S
    Rotary Tool Mount by Daturat100r
    Tangent Angle Finder by nova_robotics
    Clevis Pin Drilling Jig by Frank S

    Frank S - you'll be receiving a $25 online gift card, in your choice of Amazon, PayPal, or bitcoin. Please PM me your current email address and gift card choice and I'll get it sent over right away.

    This is your 8th Homemade Tool of the Week. Here are all of your Homemade Tool of the Week winning tools. Congrats again


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