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Step 2Cuttin' Metal
The first thing was to take the brass hexagon bar stock and cut it into 2 inch lengths.
As mentioned, there are many ways of cutting brass bar stock to length. I used a table saw and non-ferrous cutting blade.
Whatever method you use, put together a jig so you are consistent on length. It doesn't have to be exactly 2 inches long, but you want your pieces to be the same size whatever that is.
On my setup, I used the sliding miter table and put a stop block at 2" from the edge of the blade. I clamped the bar stock down with two C-clamps, put on my safety glasses and raised the blade so it would make the cut in one pass. If you try for multiple passes you will get a jaggy cut. If I did it again I would put a rag between the C-Clamps and the brass for padding and so the brass doesn't get dinged up more than can be helped. Brass is a soft metal and can get scratched up easily.
If you are doing it by hand with a hacksaw and miter box, put a stop block in place and clamp it and the brass as well. Take it slow and try and keep the hacksaw at 90 degrees to the brass.
When cutting metal using a lubricant is a good idea so I sprayed my blade and the brass with WD-40. This keeps the blade cooler and makes a smoother cut. A light spray of WD-40 would be helpful even doing it by hand.
When you are all set, put on the safety glasses, stand to one side and very slowly push the miter slide forward. Take your time. The blade will be spitting out little bits of brass and hitting you in the chest and arms - no big deal but know it's coming. Brass can really "grab" a blade when being cut so slow and easy is the ticket.
Now that we have the brass pieces cut to length, it's time to get them prepped for etching.
As mentioned, there are many ways of cutting brass bar stock to length. I used a table saw and non-ferrous cutting blade.
Whatever method you use, put together a jig so you are consistent on length. It doesn't have to be exactly 2 inches long, but you want your pieces to be the same size whatever that is.
On my setup, I used the sliding miter table and put a stop block at 2" from the edge of the blade. I clamped the bar stock down with two C-clamps, put on my safety glasses and raised the blade so it would make the cut in one pass. If you try for multiple passes you will get a jaggy cut. If I did it again I would put a rag between the C-Clamps and the brass for padding and so the brass doesn't get dinged up more than can be helped. Brass is a soft metal and can get scratched up easily.
If you are doing it by hand with a hacksaw and miter box, put a stop block in place and clamp it and the brass as well. Take it slow and try and keep the hacksaw at 90 degrees to the brass.
When cutting metal using a lubricant is a good idea so I sprayed my blade and the brass with WD-40. This keeps the blade cooler and makes a smoother cut. A light spray of WD-40 would be helpful even doing it by hand.
When you are all set, put on the safety glasses, stand to one side and very slowly push the miter slide forward. Take your time. The blade will be spitting out little bits of brass and hitting you in the chest and arms - no big deal but know it's coming. Brass can really "grab" a blade when being cut so slow and easy is the ticket.
Now that we have the brass pieces cut to length, it's time to get them prepped for etching.
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