How best to.......?

[Paul.]

Is the outside piece the cut out piece from the inside?

No its a piece separately made, the chain drilling destroys the piece cut out, also the outer half has to be just a tad longer than the cut out to give something to weld to,

 

[MoreWellie]

that might work, I can try a test on an odd bit

if you have any transparent parcel tape or just wide sellotape then cover the panel before using the jigsaw as this will minimise any chance of scratching the surface with the jigsaw plate

 

[slim_boy_fat]

Got some jobs/errands done this a.m., then cut the grass [it was as dry as it'll get more the year] so in for a bite and back out to tackle this. The black areas are the ones I want to be gone





I'm going to run a 'test' using different methods first. Wish me luck.........

 

[Wallace]

A nice little filing job.

 

[slim_boy_fat]

Well, failed miserably on all counts Hands up all those who said it'd not end well.......
Mill with small end mill = No
Chain drilling = No
Dremel + diamond blade = No
Dremel + diamond pointy thing = No
Pillar drill + 'roughing' [?] drill = No
Jigsaw + metal blade= No

At least no blood was shed in the making of this debacle.

What Paul says. How thick is the stainless, would 2mm brass be better? If I had time I could use the CNC engraver!

Was that a serious offer, Mike? If so, I could PM a file attachment, but it's a simple Word file done in the windows 'Stencil' font sized up to 220.

Failing that, it'll be back to the drawing board and possibly mild steel which ought to be much easier, and might polish up well. I just fancied the stainless. The best laid plans o' mice etc........

 

[Paul.]

You should probably use a thinner material, 3mm stainless is not an easy material to work with, and is very hard on power tool bits, I would probably have used 1.2 or 1.5mm, certainly no thicker,

 

[slim_boy_fat]

You should probably use a thinner material, 3mm stainless is not an easy material to work with, and is very hard on power tool bits, I would probably have used 1.2 or 1.5mm, certainly no thicker,

I only have what a skip will allow to escape.

 

[Wallace]

Was that a serious offer, Mike? If so, I could PM a file attachment, but it's a simple Word file done in the windows 'Stencil' font sized up to 220.

Failing that, it'll be back to the drawing board and possibly mild steel which ought to be much easier, and might polish up well. I just fancied the stainless. The best laid plans o' mice etc........

Time would be a constraint to get it done before the birthday and I would have to use a font from the machine not your file, I will check in a bit if that stencil type font is in there. I could punch the majority of it out from your stencil by hand at work in 1.5 brass or stainless or 2mm brass and post it up to you?

 

[Wallace]

Alfa192 in the fonts. Could someone pop in to Staines and remove the rod I made for my own back?

 

[slim_boy_fat]

Time would be a constraint to get it done before the birthday and I would have to use a font from the machine not your file, I will check in a bit if that stencil type font is in there. I could punch the majority of it out from your stencil by hand at work in 1.5 brass or stainless or 2mm brass and post it up to you?

If you could do that I'd be very grateful, I should have thought of this idea before the last 2 x weeks

Here's a couple of pics of the size it currently occupies but anything close in 2mm brass would be brilliant. Happy to pay the going rate, naturally. Anything further you need me to do, please shout. PM on way with details.

 

[Bladevane]

@slim_boy_fat It sounds as if you have your supply chain resolved but if you need a second option I have 4mm stainless or 3 mm mild steel I can CNC plasma cut to size with the letters as per attached.

 

[slim_boy_fat]

Many thanks, that looks excellent. Depending on how @Wallace is placed I may get back to you.
Can't believe I left it so late for this

 

[Wallace]

I can’t believe nobody has done a “giving wood” joke. Yet.

 

[slim_boy_fat]

Just to finish this off, a big shout out for Mike @Wallace for his help in doing the plaque in brass for me

Which, with the addition of a piece of oak, became this

Tricky to photograph because of unwanted reflections, but I'm sure you get the idea. Just hope she likes it......