This Instructable will show you how to make a cheap jig for cutting glass bottles. It's not pretty but it works great and will take you only a few hours. The only "special" tool you'll need for this is a drill bit that can cut through 0.25" of metal. The jig is adjustable to fit most bottles.
Parts that you will need:
1) ~2 feet of 2x4.
2) Small sheet of plywood. The exact size isn't real important but it needs to be about 6" longer than the longest bottle you want to cut and 6" wide. My sheet is 2'x6".
3) Plumber's epoxy putty (~$2 at your local hardware store). You'll need ~ 1 oz.
4) Cheap glass cutter ($6 on Amazon).
5) 0.25" bolt, 6 inches long.
6) Wing nuts and two large washers for 6-inch bolt.
7) Rubber leg tips ($1.50 at Home Depot).
8) Five 3" wood screws and one 1" wood screw.
9) Small washer that can fit inside the rubber leg tip. I used a plastic one.
10) Small cloth rag.
Tools: The normal stuff like drill + bits, screwdriver(s), and saw. As noted above you'll need a bit that can drill metal.
Parts that you will need:
1) ~2 feet of 2x4.
2) Small sheet of plywood. The exact size isn't real important but it needs to be about 6" longer than the longest bottle you want to cut and 6" wide. My sheet is 2'x6".
3) Plumber's epoxy putty (~$2 at your local hardware store). You'll need ~ 1 oz.
4) Cheap glass cutter ($6 on Amazon).
5) 0.25" bolt, 6 inches long.
6) Wing nuts and two large washers for 6-inch bolt.
7) Rubber leg tips ($1.50 at Home Depot).
8) Five 3" wood screws and one 1" wood screw.
9) Small washer that can fit inside the rubber leg tip. I used a plastic one.
10) Small cloth rag.
Tools: The normal stuff like drill + bits, screwdriver(s), and saw. As noted above you'll need a bit that can drill metal.
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Signing UpStep 1: Bottle stabilizer
This part of the jig helps hold the bottle in place while you cut it.
1) Cut a hole into the bottom of the rubber tip. You want the hole just big enough to fit the 6" bolt.
2) Insert the bolt. We want the tip to be able to rotate freely so we need to in insert something to keep the epoxy from binding with the bolt. Stuff a washer into the rubber tip so that it lays flat against the head of the bolt.
3) Cut off a good chunk of the epoxy and knead it so the two parts mix up well.
4) Stuff the epoxy into the rubber tip as tight as you can and form it into a rounded cone.
Set it aside to allow the putty to harden.
1) Cut a hole into the bottom of the rubber tip. You want the hole just big enough to fit the 6" bolt.
2) Insert the bolt. We want the tip to be able to rotate freely so we need to in insert something to keep the epoxy from binding with the bolt. Stuff a washer into the rubber tip so that it lays flat against the head of the bolt.
3) Cut off a good chunk of the epoxy and knead it so the two parts mix up well.
4) Stuff the epoxy into the rubber tip as tight as you can and form it into a rounded cone.
Set it aside to allow the putty to harden.
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I linked to the youtube video on account of... I don't THINK he posted it on THIS site under his account. Jump to 6:15 for the down and dirty of it.
It really does take longer to watch the 10 min video than it does to score, separate, and sand the finished product.
Anyhow, let me tell you... this is the EASIEST method I've ever tried.
Using a wet-tile saw or glass cutting band saw gives you more flexibility(like being able to cut bottles at a nice angle) and NO chipping/stress cracks.
Abrasive machining of glass is nice, but it can be pretty pricey, time consuming, and for straight cuts, don't work any better.
If you do champagne bottles, you need FRESHLY boiling water, and it will take longer.
The number of rings you can score is limited by the length of the bolt for the stabilizer.
The SOLUTION to this issue is to either make the scoring tool adjustable(like using a c-clamp to hold it onto the board, instead of a screw) or to replace the bolt with a length of all-thread, making the stabilizer infinately adjustable(Well, unless you're trying to cut one of THESE http://cdn.emergingmoney.com/wp-content/uploads/2012/01/Giant+Bottle+Bordeaux+Wine+Set+Auctioned+Sothebys+6ovJnBQdaoWl.jpg)