Stack-Cutting Miniature Parts with a Scroll Saw
I was asked how to cut several parts at once with a scroll saw. Stack-cutting is a time-honored tradition and there are a number of ways in which people hold a stack of wood together while cutting several pieces simultaneously. For miniatures, however, I’ve settled on this approach as it suits the small size of the parts we’re trying to cut.
Step 1: Cut some blanks that are a bit larger than your template. If your blade is set perpendicular to the table, and if you can cut without applying so much pressure to the blade such that it bows, you can cut at least 3/4″ worth of parts. In 1/12 scale we’re typically working with 1/16″ wood so, theoretically, you could cut 12 parts at a time. In smaller scales, of course, even more. I’m not sure why but I typically limit myself to cutting 6-8. Maybe it’s because every error you make with this technique is multiplied by the number of parts you’re cuttting (grin).
Step 2: Stack up your blanks and wrap them with blue painters tape. I prefer the blue tape as it is easier to remove than typical masking tape but it probably doesn’t matter much what kind you use. As you do this, try to keep the surface that will be on the table as flat as possible by having only one layer of tape on that surface with little overlap.
Step 3: Use a glue stick to stick the template to the stack and you’re ready to cut. All that’s left is to cut to the template. When you’re done, the parts will likely still be held together by some of the tape. While I didn’t take the time to do this here, this is a handy time to sand any cutting errors and maybe even finish-sand the edges. Then just peel off the tape.
Cheers — Larry
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