Cutting Thick Brass — SOLVED!

[Matt Walters]

Yep. Sometimes I too have to buckle down and just file & sand until I get a piece to look like I want.

[the elephant]

Matt, it is a relief to know that someone of your skill level with a shop as well-outfitted as yours still has to physically "gut out" some operations, on occasion.

I feel precisely 1.75382 smidgens less rednecky. HAHAHA!!!

[Yorkboy]

Not exactly the same, but the same idea:

C4BF0DD0-F828-4733-9411-C6C8DFB9D76A.jpeg (105.06 KiB) Viewed 282 times

I cut the raw piece with a jigsaw, then ground it to shape by eye on the bench grinder, then finished it with a lot of filing and sanding. The plate was formed with sheet brass and then hard soldered on.

It took a LOT longer than I wanted it to

Final product, adjusted a little:

E42CBB10-E0C1-4D61-8471-82C5610E71E5.jpeg (132.59 KiB) Viewed 279 times

[the elephant]

Same joint exactly. Excellent!