I think that I'll start a Zombie Apocalypse store

[the chi]

That is flipping awesome PC!! I totally want some chain mail now...

[njchopper87]

Looks like you're having fun with that. Good job!

[Papa_Complex]

Originally Posted by Turbo Ghost

Pretty cool! Is the blade a diamond blade on a router? If so, is the router variable speed and what speed are you running?

I had originally thought about using a variable speed router but after checking the proper cutting speeds needed, I chucked that idea. Instead I'm using a keyless chuck hand drill in a homemade clamp, with a 0.008" thick, 1.75" diameter steel jeweler's saw blade.

When cutting aluminum wire I'm running somewhere around 400 rpm but I don't have a laser gauge, so that's only an estimate. I control the speed by plugging the drill into a router speed control box.

Originally Posted by the chi

That is flipping awesome PC!! I totally want some chain mail now...

I didn't realize that you were back! Good to see you

Something like 16 gauge, 1/4" links of aluminum makes for a great costume grade suit of chainmail. It weighs roughly a third of what actual steel would. That full chainmail weighs about 20 pounds. The halter I made weighs in at less that 8 pounds (maybe around 6) and both the women who tried it on, my model for the pictures and a friend who is big on cosplay, said that they barely noticed it while wearing it.

Doing this has also resulted in a skill that has made me pretty popular

Originally Posted by njchopper87

Looks like you're having fun with that. Good job!

Thanks, I'm definitely enjoying this. Everything from the tool building to the final product. While typing this I actually have another project sitting on my table a few feet away; a scalemail short that will make for a better Hallowe'en costume, because it's much lighter.

[Turbo Ghost]

[QUOTE=Papa_Complex;531554]I had originally thought about using a variable speed router but after checking the proper cutting speeds needed, I chucked that idea. Instead I'm using a keyless chuck hand drill in a homemade clamp, with a 0.008" thick, 1.75" diameter steel jeweler's saw blade.

When cutting aluminum wire I'm running somewhere around 400 rpm but I don't have a laser gauge, so that's only an estimate. I control the speed by plugging the drill into a router speed control box.



QUOTE]

Ah! I didn't realize you were using aluminum! I was thinking you were using steel and figured you'd need the power of a router to cut that quick.

[Papa_Complex]

Originally Posted by Turbo Ghost

Ah! I didn't realize you were using aluminum! I was thinking you were using steel and figured you'd need the power of a router to cut that quick.

I can run much higher speeds than I do when cutting aluminum but the funny thing is that the tougher the metal, the lower the speed that you cut it with. The routers that I checked, including my own, were up in the 10,000 rpm range. Aluminum should be cut at no more than about 1,000 rpm with the size of blade I use. I also routinely cut brass, which should be cut at around 200 rpm. Mild steel is about the same as brass. Mid strength Ti or stainless steel is around 100 rpm, but I haven't tried them yet. no idea if my current rig can handle it.

[Turbo Ghost]

Those router speed controls come in handy don't they! I have one I use for a lot of different things. I've even used it on my hand-mixer when the lowest speed was too fast for the recipe!