Sawing Symmetrical Shapes

I’ve been frustrated in the past with the failure to make pieces sawn with a jeweler’s saw match correctly (not even a file could remedy some situations!). I’d tried using rubber cement to adhere two pieces of metal together. I couldn’t make it work no matter what I did. Enter cyanoacrylate, AKA Super Glue. Yes, one must be diligent in using this wonder adhesive, as I am sure many of you may have unintentionally attached fingers to fingers, fingers to other objects or objects to other objects. And I am sure those who have done this know that acetone based nail polish remover will help dissolve the adhesive.

This technique is super easy and will yield symmetrical shapes that are particularly desirable for earrings for those who prefer a matched pair. I have used this technique on copper, aluminum and bronze.

Materials:

Sheet metal of your choice, 22-gauge and 24-gauge work the best

Tools and Equipment:
– Metal shears
– Cyanoacrylate adhesive
– 400 grit sandpaper
– Small clamps – These can be found on our sister site JewelryTools.com
– Permanent marker
– Jewelers saw with #1 metal cutting blade
– Beeswax or cutting lube
– Bench pin
– Acetone based nail polish remover
– Metal file

Decide what pattern or shape desired.

Using the metal shears, cut two pieces of sheet metal slightly larger than the pattern.

Lightly sand the pieces using the 400 grit sandpaper; this will give the sheet metal some tooth. Tip: if you are using sheet metal heavier than 24-gauge you may find that there is a small lip left on the cut edges. Just make sure you align the pieces so that the edges with the lips face away from one another. This will assure a tight bond.

Place two or three drops of the cyanoacrylate adhesive on one piece.

Place the other piece of sheet metal on top of the adhesive, making sure they are aligned, apply pressure using a small clamp.

Let the piece sit a few minutes to make sure the adhesive cures.

Transfer the design to the metal using a permanent marker.

Saw out the design and smooth the edges with a metal file and sandpaper.

Place the piece in a small dish containing a small amount of nail polish remover and let it soak. After approximately 5 minutes, remove the piece and pop the pieces apart. Return to the polish remover to remove the residual. You may need to coax the residual with 400 grit sandpaper. Wash with dish soap to remove any trace of polish remover.