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Slot Cutting

Posted: Mon May 23, 2016 7:24 pm
by DocAitch
LL hinted at a slot cutting template in a recent post, so I had to give it a shot.
I used a Strong Tie ($2 t Home Depot), drilled and filed a 1/16" x 1/2" slot, made a V channel from scrap, cut some shims, and C clamped my drilled rod in place.Image
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I cut the slot with a Dremel and 1/16" bit
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I also made some sanding sticks with hack saw blades and glued sandpaper on with silicon adhesive.
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I can now cut, file, sand and polish my slot in less than 1/2 the time. I did 6 of these in about an hour today (which may not sound like much to you guys, but for me it was racing).
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Thank you, George
DocAitch

Re: Slot Cutting

Posted: Mon May 23, 2016 7:35 pm
by clickklick
That is ingenious!

Re: Slot Cutting

Posted: Mon May 23, 2016 7:58 pm
by LatakiaLover
For those who missed it, here's the most repeatable and consistent solution posted on this board to date:

viewtopic.php?f=43&t=8137&p=74887&hilit=slot#p74887

Looks like Doc split the difference down the middle between the freehand method and Red's.

Re: Slot Cutting

Posted: Mon May 23, 2016 9:39 pm
by PremalChheda
LatakiaLover wrote:For those who missed it, here's the most repeatable and consistent solution posted on this board to date:

viewtopic.php?f=43&t=8137&p=74887&hilit=slot#p74887

Looks like Doc split the difference down the middle between the freehand method and Red's.
Martin & Anders have a very similar setup. However, after cutting so many slots by hand with the same tools, it is controllable and just as fast.

Re: Slot Cutting

Posted: Mon May 23, 2016 9:40 pm
by DocAitch
Oklahoma Red has more machining skills than I do, and more time than I would spend on this device, but it does make more repeatable results.
Mine works pretty well for a couple of bucks and about an hours time.
DocAitch

Re: Slot Cutting

Posted: Mon May 23, 2016 10:12 pm
by Ocelot55
Very cool, Doc! As my pappy always said, "That's usin' yer head fer more than a hat rack!" :thumbsup:

Re: Slot Cutting

Posted: Tue May 24, 2016 6:42 am
by baweaverpipes
However, after cutting so many slots by hand with the same tools, it is controllable and just as fast.
Yep!

Re: Slot Cutting

Posted: Tue May 24, 2016 11:47 am
by mji.ipour
Tank so much Doc.


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Re: Slot Cutting

Posted: Wed Apr 26, 2017 10:06 am
by BriarShrink
DocAitch wrote:LL hinted at a slot cutting template in a recent post, so I had to give it a shot.
I used a Strong Tie ($2 t Home Depot), drilled and filed a 1/16" x 1/2" slot, made a V channel from scrap, cut some shims, and C clamped my drilled rod in place.Image
Image
Image
I cut the slot with a Dremel and 1/16" bit
Image
I also made some sanding sticks with hack saw blades and glued sandpaper on with silicon adhesive.
Image

I can now cut, file, sand and polish my slot in less than 1/2 the time. I did 6 of these in about an hour today (which may not sound like much to you guys, but for me it was racing).
Image
Thank you, George
DocAitch
Wow. After fumbling around with my first slot...this is pretty cool!

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Re: Slot Cutting

Posted: Tue Jun 06, 2017 11:54 am
by DocAitch
OK, so I used this jig for about 20 stems and the following problems have become apparent.
1) unless the Dremel is very carefully kept in the same plane, the internal surface of the funnel gets sloppy and uneven, and if you really fall asleep, you can cut a false passage.
2) the height of the slot tends to become a bit larger than desirable, especially when some wear develops in the slot of the jig, which is very soft metal.
After producing a number of less than perfect slots, this jig has been consigned to the growing pile of junk under the bench and I have gone to cutting my slots with a funneling tool. It is a bit more laborious and time consuming, but the slots are much cleaner and narrower, and the internal geometry is much nicer.
Oklahoma Red and Benniesam have both produced jigs which eliminate these two errors.
I apologize for leading anybody down this particular garden path.
DocAitch

Slot Cutting

Posted: Fri Aug 07, 2020 11:31 pm
by Blackbeltpipes
DocAitch wrote:OK, so I used this jig for about 20 stems and the following problems have become apparent.
1) unless the Dremel is very carefully kept in the same plane, the internal surface of the funnel gets sloppy and uneven, and if you really fall asleep, you can cut a false passage.
2) the height of the slot tends to become a bit larger than desirable, especially when some wear develops in the slot of the jig, which is very soft metal.
After producing a number of less than perfect slots, this jig has been consigned to the growing pile of junk under the bench and I have gone to cutting my slots with a funneling tool. It is a bit more laborious and time consuming, but the slots are much cleaner and narrower, and the internal geometry is much nicer.
Oklahoma Red and Benniesam have both produced jigs which eliminate these two errors.
I apologize for leading anybody down this particular garden path.
DocAitch
I’ve had the funneling tool “run”
On me... it seems the best solution for me so far has been something I briefly saw on a JAlan video where he seems to use a drill bit to widen the funnel. I found some folks talking about using drill bits from different manufacturers that seem to have a more side cutting friendly design. I gave it a shot on my drill press letting it side cut in the press and it has changed that task for me immensely. It’s not aggressive so I like how it slowly travels through the material. Have you had any luck with this or heard of it before? I’m focused on making stems right now and I’ve been trying all different techniques in search of the way that fits me best, so if you have any advice I’m all ears...!
...also if I chuck the bit correctly, I can put the bit into the slot far enough so the smooth end of the bit doesn’t cut into the finished edges of the slot opening. Another plus I’ve found...


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Re: Slot Cutting

Posted: Sat Aug 08, 2020 1:21 am
by LatakiaLover
Get the side-cutting bit shown here from RawKrafted.com:

https://www.youtube.com/watch?v=8IoAFf2 ... =8&t=4m23s

Re: Slot Cutting

Posted: Sat Aug 08, 2020 11:55 am
by Sasquatch
Get some masking tape.

Re: Slot Cutting

Posted: Sat Aug 08, 2020 3:01 pm
by DocAitch
As I noted in my last post above, that jig is sitting in the pile under the bench. I mark my slots with tape, as Sas suggests, and sometimes use a circular cutter to cut a guide, then I use a funnel saw. It takes a few minutes, but the slots are better and the internal geometry is much better and more consistent.
I have watched Premal Chheda cut a slot using his side cutting bit make a slot and funnel in a minute or so, and regret that I don’t have the skill to control the unseen end of the bit to keep the funnel in the same plane. I did make a device attempting to use the same principles as Oklahoma Red did, but there were too many variables, and too much slop.
Cutting a slot by hand, although it seems a huge thing from a beginner’s viewpoint, becomes inconsequential when you are a bit further down the road.
DocAitch.

Re: Slot Cutting

Posted: Sat Aug 08, 2020 6:04 pm
by Doug535
If you can get the feel for the sidecutting bits, you can do a funnel from the 1/16 pilot hole to filing and sanding the slot then polishing in about 10 minutes. I do use the dremel #199 saw to cut initial slot also.

Re: Slot Cutting

Posted: Sat Aug 08, 2020 10:44 pm
by DocAitch
I am pretty sure that I can get used to side cutting bits, it will just take some practice, and I don’t really feel like wasting the rod to practice. I like my methods as of now.
DocAitch

Re: Slot Cutting

Posted: Sun Aug 09, 2020 6:53 pm
by n80
I have a couple of bits I use for this. I do not know where they came from. They are not side cutting bits. They look like normal bits. But they side cut extremely well. Before I found them in my large pile of (mostly trash) bits, I was considering buying some side cutting ones but these work so well I no longer feel the need.

I mark all 4 edges of the slot with masking tape. I drill the center hole with one of these bits. Then I cut the slot with one of those little round Dremel saw blades. Put the same bit that I drilled onto the Dremel tool (wish I had one of those low speed/high torque deals but it is not in the cards right now.) Insert it into the draft hole previously drilled and slowly arc it left to right keeping within the bounds of the masking tape and that forms the funnel fairly nicely. After that it gets all fiddly and tedious but my results are getting better and better.

I think if I had one of those low speed/high torque deals this process would be nearly ideal. At least for a beginner hobbyist.

Re: Slot Cutting

Posted: Sun Aug 09, 2020 7:19 pm
by Blackbeltpipes
n80 wrote:I have a couple of bits I use for this. I do not know where they came from. They are not side cutting bits. They look like normal bits. But they side cut extremely well. Before I found them in my large pile of (mostly trash) bits, I was considering buying some side cutting ones but these work so well I no longer feel the need.

I mark all 4 edges of the slot with masking tape. I drill the center hole with one of these bits. Then I cut the slot with one of those little round Dremel saw blades. Put the same bit that I drilled onto the Dremel tool (wish I had one of those low speed/high torque deals but it is not in the cards right now.) Insert it into the draft hole previously drilled and slowly arc it left to right keeping within the bounds of the masking tape and that forms the funnel fairly nicely. After that it gets all fiddly and tedious but my results are getting better and better.

I think if I had one of those low speed/high torque deals this process would be nearly ideal. At least for a beginner hobbyist.
I’m with you... however I use my drill press that is at eye level and I can hold the stem with two hands... it’s a low speed high torque option that I feel I have good control of. I won’t switch until I’m forced to. I also found normal bits with side cutting ability so for now I refuse to let them out of my sight lol... I do the same by just rocking the stem stock back and forth until the slot is where I want it. I like having two hands to hold the stem because mainly, I am able to keep myself from deviating within the slotted funnel and getting too wild inside the stem.


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Re: Slot Cutting

Posted: Mon Aug 10, 2020 5:38 am
by Odissey
Good day!

I'm definitely not the best stem cutter. Without a lathe, this becomes a rather difficult job.
But I kind of developed my own technology for making a slot in the stem. I use my drilling machine with a two-axis vise for this. On the last stem I made, I broke a 1.5 mm carbide cutter, but I already ordered a new one. She will come to me after the 15th. Then I will try to take some photos and show how I make slots up to 45 mm deep.

Respectfully, Odissey