>>755I had some old and dull hacksaw blades and with missing teeth. I used to cut lots of metal with the hacksaw and never threw the blades away. It took about 10 minutes each one.
I cut the stencil carefully, then laid it over the blade, applied a dab of paint and slided it down the blade with a piece of paper to transfer the shape. When the paint is dry I cut it with the dremel disks, specially useful for the straight zones. You have to be careful and wear eye protection because they tend to get stuck and shatter at high speeds. For the groves I kept using the disks because it was more precise than the sanding cylinder. I just vised the dremel and I held the pick against the spinning disk.
I tried to avoid getting it too hot while cutting it and I was constantly wetting it with a napkin to conserve the heat treatment.
This was the first one I made. I used sand paper to soften the edges. I also sanded the sides to make it thinner and easier to use.
