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Subject: Board cutting - jigsaw ends rss

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Raven Morpheus
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Hello again

So, in my ongoing attempt at putting together a "homebrew" Space Hulk set I'm getting there, but it's taking some time...

It's taking some time because cutting the board tiles seems to take me forever to do it.

I am using 2mm greyboard to mount my printed labels with the artwork on and I can only do about 2 A4 sheets worth of board tiles per hour before my hands cramp up from holding my craft knife, mostly due to cutting the jigsaw ends.

So, I'm wondering, is there a way to cut the jigsaw ends on the board tiles quicker and easier than by hand with a craft knife?

Perhaps a die tool or something? I don't have any power tools and investing in a band saw or something similar would be rather cost prohibitive, if it would even work to cut greyboard without making a mess of it.

Thanks in advance.
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Luke Stirling
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Unless you know someone who has access to the hardware to do it, it's expensive, but the obvious solution to me is laser cutting.
 
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Brent Lloyd
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I bet this baby would work great - I am gonna get one and give it a try. It looks affordable and stores away in a small package when not in use.

http://www.dremel.com/en-us/tools/pages/ToolDetail.aspx?pid=...

The reviews on YouTube and such seem glowing. I am pondering using that same material that Pegboards are made out of, dark-ish brown smooth on one side stuff. Then gluing printouts on top.

Peace
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Raven Morpheus
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Thunder wrote:
I bet this baby would work great - I am gonna get one and give it a try. It looks affordable and stores away in a small package when not in use.

http://www.dremel.com/en-us/tools/pages/ToolDetail.aspx?pid=...

The reviews on YouTube and such seem glowing. I am pondering using that same material that Pegboards are made out of, dark-ish brown smooth on one side stuff. Then gluing printouts on top.

Peace


Probably would work ok for greyboard also. But I live in the UK so shipping from the US would be expensive, and no doubt similar items available in the UK cost far more than they should do, we get right royally ripped off when it comes to DIY/hobby tools and materials.

Besides, even $90 (£53ish GBP) is a bit of an expense I can't really go to just for some board tiles.

I'm guessing I'll have to just soldier on. I was hoping someone might know of a really cheap but easy way to do it, but I'm guessing there isn't one.

Good tool though, never seen one of those before, I have a cheap nowhere near as robust/powerful "Dremel" clone but I've never come across a saw attachment like that.
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Brent Lloyd
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That is not an attachment, it is a stand alone tool.

You ought to be able to cut greyboard with a Dremel, give it a try.

Peace
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Raven Morpheus
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Oh I see. I only briefly looked at it, thought it attached to the dremel. I wondered how a rotary head would translate to the vertical motion required for a saw blade.


I hadn't actually considered using a dremel due to the nature of the cuts needed, thought it'd be too awkward.

I may give my "dremel" clone a go though and see what result I get, but I've only got the standard "carbide" cutting disks. Luckily I have some spare greyboard off cuts I can test on. Might work though, even just for the jigsaw ends, the straight edges I can cut by knife easily enough, they're the easy part and I'm considering just cutting the straight edges out just to get all the board tiles I've printed to a usable state then "revisit" the jigsaw ends at a later date.

At the rate it's taken me to cut the board tiles I've printed so far I'm actually considering copping out and buying a set of board tiles from ebay, probably should have done that to start with, I could have had a set of 3rd edition tiles/doors/counters for what I've paid so far for what I've printed, I think, and then just printed off the extras I've added myself (1st edition deathwing/genestealer extras like the really big 4x4 rooms and some extra corridors).

Ho hum, we live and learn...
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Brent Lloyd
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I have has success cutting 1/4" solid wood into some intricate shapes using a Dremel and this bit:

http://www.dremel.com/en-us/Accessories/Pages/ProductDetail....

The solid wood is going to be harder than the Greyboard - so if you go slow it should make a smooth even cut. If you go fast it might rip and tear.

Post back here with your results, I am interested in seeing how this worked out.

Peace

PS. No, I don't work for or own any stock in - Dremel! It's just a great hobby tool for small boardgame and miniature projects like this.
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Raven Morpheus
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Will definitely post back with results. Might be a couple of weeks before I do though due to other things taking up my time, but I'll definitely post results, hopefully good ones...

Will try the discs I've got first before investing in another bit, they're only £5 ($8ish) on Amazon but that still another £5 I may not need to spend if I can help it.

Thanks for the tips.



Found this vid on youtube of that bit in use - looks brilliant. As long as I take it slowly I should get the right shape jigsaw quite easily, and quickly. With a bit of practice...

https://www.youtube.com/watch?v=nF8-SV6ZA0M
 
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Isn't there a way to add a flush trim bit to a Dremel? Then you could use the multi-cut bit to mock up the template, and use the flush trim bit to make it all perfectly repeatable.
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Brent Lloyd
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crambaza wrote:
Isn't there a way to add a flush trim bit to a Dremel? Then you could use the multi-cut bit to mock up the template, and use the flush trim bit to make it all perfectly repeatable.


This would be optimal for sure - making a template.

Peace

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Michael Melbourne
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I used nail clippers around the puzzle parts of my boards. Much easier than trying to use an X-acto blade. They were concave, which made the outer corners easy to follow. I would just chip away at it. Then clean up as needed with a blade.
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Raven Morpheus
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Good idea with the template and flush fit bit. Didn't really consider that but yes that would be optimal, providing I can find a bit of wood or something significant to make the template from.


I can find router flush trim bits for dremels on Amazon, but I don't really know what I'm looking at...

What sort of size, head, blade, shaft etc. are we talking about?

I'll continue looking into this idea as it seems the best so far.
 
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Slev Sleddeddan
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I've been planning to make myself some extra board pieces, and hatched a cunning plan!
I'm going to trace a join form the existing set as a digital template, and get many laser-cut in wood. These will then be stuck onto card with the designs on.

Note as I',m only getting the joins cut (the back end being flat, the laser cutting costs are lower since it's just a lot of a single design.
 
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Raven Morpheus
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Slev wrote:
I've been planning to make myself some extra board pieces, and hatched a cunning plan!
I'm going to trace a join form the existing set as a digital template, and get many laser-cut in wood. These will then be stuck onto card with the designs on.

Note as I',m only getting the joins cut (the back end being flat, the laser cutting costs are lower since it's just a lot of a single design.



Care to share where you would get them laser cut? To my mind doing so would be very cost prohibitive, even for just your idea of just the jigsaw ends, because private companies I've seen charge an arm and a leg for such custom work.


BTW guys I had a go with my dremel and failed. It just makes a mess of the greyboard, at least it did for me. It would probably work with something stiffer/less fibrous but doesn't seem to me to be the solution to cutting greyboard.

I am going to have to plod on with cutting by hand - I think to save myself time so I can at least use the set I will cut the ends straight and then at a later date go back and do the jigsaw ends when/if I feel like it.

Many thanks for the advice on this though guys, sorry I didn't report back on my findings with the dremel method sooner.
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Slev Sleddeddan
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There's a place near here that has lazer cutters, lathes, etc, that gives free time to hobbyists.

Failing that, lots of the same shape is quite easy if digitised, and *relitively* inexpensive.
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Ian McCarthy
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I made my Jigsaw ends using sharp, heavy duty sewing scissors and a razor sharp hobby knife. You cut the straight outer parts with the scissors and then do the inner straight with several passes of the hobby knife. Finally you poke into and sort of saw through the inner curves. Trim as necessary.

It is time consuming, but I did it all free hand this way after several initial failures. I'm on my phone, so maybe I'll edit in a picture of the completed project later.

*Edit* Here is my set. It is 120% bigger than the real deal.



So, looking at the jigsaw end. Cut in from the left and right with scissors, then do the three vertical cuts, the middle one being angled inward. Cut off the straight edge of the protruding puzzle end. Then, do all the inner stuff with your razor sharp hobby knife. I used the common X-Acto blade.
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