cutting grooves into materials without milling tools?

Wes R

Legendary Member
I'm working on a handle for a sword replicating Megatron's energy blade from the 1986 Transformers movie and i'm prototyping it with stuff around the house. The issue is the handle has grooves in it like it was turned on a lathe and i have no idea how to replicate them by hand. Ideas?
 
astroboy, sounds to me like you need some panel scribers. I use the back of an Xacto knife but there are proper scribing tools out there.

Wes, do you have a pic of what you are trying to create? To copy a mill or lathe requires different techniques.
 
I say a rasp and a steady hand. Or an electril drill or a dremel in a vise and the rotate the handle bar along the drill bit. But make sure the drill points away from you, and that you have some kind of guide on the handle so that it does not turn.
 
astroboy, sounds to me like you need some panel scribers. I use the back of an Xacto knife but there are proper scribing tools out there.

Wes, do you have a pic of what you are trying to create? To copy a mill or lathe requires different techniques.
thanksS


do you tape on a metal ruler or something?
 
I actually thought about the drill. I have an old cordless that's dying so maybe i could use that and make a jig to hold the piece and have it turn like lathe. Once i get the lines drawn on straight it should be pretty easy to go from there. if i didn't suck at 3D programs i'd just model it.
 
I'll get some pics tonight of it. I can't find any screen caps of the sword that are really good for some reason.
 
I've had great success using the edge of a steel hose clamp (from any hardware store, available in a wide variety of diameters) as a guide for scribing grooves into round stock.
 
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Here we go. They don't have to go too deep. My art skills are horrid so i'm trying to make as much as i can instead of hiring someone to make them in cad to be sent to shapeways and I can't get a grasp on any of these 3D programs. I miss the idiot proof 3D cad program i had years ago.
 
Hmm..

The first thing that leapt out of my mind was "Pipe cutter", but that's pretty much only if you are using PVC. It would get you started pretty well though.

I don't remember that saber looking like that, though. Of course, it's been at least a year since I saw the movie :lol

Rasps might be your best bet on this project. Get the lines laid out, and just patiently file. It's going to take a bit, but hey, awesome takes time :)

Chris
 
lol. I have the animated movie next to my desk. I looked at lowe's but shockingly they didn't have those clamps in a size/price i liked and the single use ones were in packs of ten. Once my dad gets up I'm going to ask him because we should have a ton of them laying around from our old cars.
 
If it were me i'd drill a hole down the center, stick a threaded rod through it, use a washer and nut on each end. Then stick one end in a drill thats held in a vise and support the other end on a V shaped block. Then use a hacksaw blade to start the lines and get a guide. Then open the grooves up with files and sand paper.

The hardest part would be securing the drill and the v blocks so they don't move.

It might not work but thats how i would try.
 
true. I also just realized i'm a moron. I have some ratty looking zipties that i could put on this and its less likely to mark up the wood than the metal clamp.
 
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