Sawing is an essential skill for a bench jeweler. This article will show you a technique that will increase your sawing speed and accuracy when you need to make sharp corner cuts and reduce your likelihood of breaking delicate saw blades.
First, be sure to observe all sawing basics. Make sure the blade is properly held in the saw frame and that it is lubricated.
In order to create a sharp corner, you can make a saw cut into the corner, then remove the saw blade and cut into the corner from another direction.
It is possible to make a crisp 90-degree corner without backtracking, however. The material you are sawing should be supported firmly on a flat and level bench pin that has a cutout for piercing. Be sure the saw blade is perpendicular to the work surface while you are cutting. If the blade is tilted left, right, forward or backward, it will distort the cut and likely break the blade.
Saw along your line as you approach the corner. When you reach the corner, stop the forward movement of the blade, but keep moving it up and down. Next, change the direction of the cut by either turning the saw frame or moving the object. It is important to keep the saw blade moving up and down as you change direction. The teeth of the saw blade, which are slightly offset, will cut the metal away as the blade is turning, allowing you to saw right around the corner without breaking the blade.
With practice, you can make sharp corners of all angles. For corners less than 90 degrees, make your turn a short distance from the corner. This will leave the corner slightly rounded, but you can just come back and make the corner crisp with a few quick saw cuts.