Well I’m back after a mini vacation and dealing with transportation issues (Blew the rings in my van and getting an old truck road worthy)

So,. here are some of the techniques I used on the snowflake project:

 

1. I only had one paper pattern for each size so I optimized the material and cut a single snowflake of each size.

 

2. Using the cut snowflakes as templates I laid out the rest of the flakes to optimize the material (keeping in mind how many of each size the customer wanted).

 

3. I started by using three sawhorses to support the 4 x 8 sheet of plywood, this allows two sawhorses to support the majority of the plywood while the third supports the opposite side of the cut. I shifted the position of the third sawhorse as necessary.

 

4. I separated each flake from the full sheet first, then went on to cut all of the flakes.

 

5. While separating the flakes I cut the outside “flats”. I could have just cut between each flake, but that would have added to the cut time, wear and tear on the saws and the number of blades that I used.

 

6. I used appropriate supports for each size of flake; for the two larger sizes I used two sawhorses, cutting in between the horses for maximum support (rotating the piece as needed). For the smaller flakes I used the workmate with the clamp jaws extended as needed.

 

7. As for the actual cutting I used a scroll blade exclusively. I can cut straight with it when needed and changing back and forth is a pain. The HF and Bosch blades held up pretty close to each other (HF was U blades Bosch was the T blades, HF did not have mutipacks of T scroll blades)(HF scroll blades were 12 tpi, the Bosch 20 TPI so the Bosch blades did cut smoother).

 

8. While cutting the patterns I used some scrollsaw tricks, When cutting a sharp inside corner I would cut to the line and then widen the kerf until I could turn the blade without stressing it. When cutting a sharp outside corner I would cut through the waste area to the line, follow it to an inside corner I had previously cut ( allowing the waste to be removed ) then cutting the other side of the outside corner (now exposed). I’m not sure how clear this is, I was working alone. Next time I’ll try to take pictures or video. I rarely think of that while I’m cutting.

Edited November 18, 20178 yr by Ron Dudelston
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Cool idea with the pattern! I never knew there were the "scroll saw" blades available for the jig saw. They would have saved a lot of Navy language on a few of my projects.