Step 3: Cutting the Rings
This method works best for 'score and bend' ring cutting. Cut the rings almost all the way through the coil, remove from jig and snap the rings off at the scoreline. (If you cut the rings all the way through, they can jam the scroll saw blade in the jig and bend or break the saw blade).
Cut coils to fit into the jig
1. Insert coil into the jig hole and press it down into the hole
2. Take a utility blade and insert it one coil above the top surface of the jig
3. Carefully bend the coil to the side.
4. Remove coil and cut the measured part of the coil just below the bend. Trim edge flush to the top of the coil.
5. Insert coil into the jig hole and make sure it sits almost flush with the top.
6. Repeat for all holes.
Screw top down using thumbnuts. OR use masking tape to secure wood to hold down the coils OR use a nail or metal rod to hold the coil down while you cut the coil.
7. Insert fine tooth metal blade into the scroll saw (40-60 teeth with as small a kerf (blade width) as you can find.
8. Start from the outer edge of the coil and make a straight cut towards the center of the coil. The first time you use your jig, you will cut through the wood before you reach the metal coil - see the marked lines in the 3rd picture below.
9. Make sure that the coil is secured so it doesn't bounce up and down as the scroll saw blade moves up and down - the coil should be held down by the wood cover, or maually held in place using a thick nail or piece of metal.
10. Saw almost all the way through one side of the coil.
Note: Thinner gauge wire may need to be supported by a wood dowel or skewer placed inside the coil.
Saw SLOWLY, applying a smooth, even pressure - go SLOW and let the blade do the work of cutting, do not push hard or you will snap the blade.