Jeweler Saw Practice

Having just finished the electronic part of installing a DCC decoder in Comstock Road’s lone Atlas O SW-8, I set out to finish the job by making sure everything was correctly insulated, taped down and able to fit inside the diecast metal shell. Perceptive readers might wonder why I mention the shell material. That is part of the fun!

Getting the wires all tucked in was not too much of a challenge but I then discovered that my estimation of clearance between speaker top and shell was, er, optimistic. The issue was the speaker mounting lugs cast into the inside of the shell. They are almost a fit for the chosen TCS speaker but only almost. I have also elected to not attach the speaker to the shell to give more clearance for a future detailed grill.

Here is what the inside looked like when I started.sw8mountlugs

Since the lugs had to go anyway, I resolved to “daylight” the opening back to something akin to the prototype rectangle. This would give plenty of room for the speaker to shoot upwards.

I got out my trusty jeweler’s saw and my excessive supply of #0 blades. Back in the day, I bought a gross of this blade size in a fit of enthusiasm and only afterwards discovered that #0 is too coarse for .015″ material. I have despaired of every finding a use for all those blades but no longer!

Even the relatively heavy #0 blades are fragile and do not tolerate careless use. You can turn corners in a cut but you have to carefully saw in place while rotating cautiously. If you push to hard you can jam the blade and snap it. Letting the work twist on the blade while repositioning can break a blade… You get the idea. Fortunately, I have about 12 dozen blades for just such an emergency. Or I did. I am now better at sawing and have less blades.expendovblades

Eventually, I got the opening cut out to my satisfaction. Here is the view from above with the shell on. (Apologies for the bad focus.)speakerhole

And here is the top view with the stock screens and grills back in place. All being black, the speaker is not visible unless you get up close and look straight.sw8postsurgery

2 thoughts on “Jeweler Saw Practice”

  1. Mark::

    You may want to take a look at the following as it explains the proper way to insert a blade into a saw frame:

    The key is to ‘flex’ the frame in order to obtain the proper tension .

    .vp

    Like

    1. If you don’t get the blade tensioned, you aren’t doing any sawing. Lubricating with wax is also highly recommended. I have yet to use the adjustability of the frame to reuse short pieces. Probably because I have about 130 #0 blades left. 🙂

      Like

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