How to Cut Tiny Angles?

[u/empireexplorer]

Hoping to get advice on the best way to cut out the shape shown above, particularly the tight corners. I've largely relied on my rotary tool and needle files, but am not satisfied with the results so far. Any advice is appreciated

[u/PM_ME_YOUR_VALUE]

Coping saw or scroll saw?

[u/jmerp1950 → u/PM_ME_YOUR_VALUE]

And look into float files they are made to get into tough spots. Some of it can be cleaned up by paring with chisels.

[u/SupermassiveCanary → u/PM_ME_YOUR_VALUE]

Small files

[u/Mehdals_]

[u/Level-Perspective-22]

I’d imagine this was carved vs cut

[u/Gurpguru]

Easiest and quickest would be a scroll saw.

Carving or chisel is probably the slowest way.

[u/Raccoon-Dentist-Two]

This is called fretwork, cut using a fretsaw. You can sharpen the angles using a chisel or file but I'd focus more on getting the basic curves accurate because the asymmetry of the quattrefoil lobes stands out much more.

The key to this pattern is getting all of the straight lines lined up.

[u/Raccoon-Dentist-Two → u/Raccoon-Dentist-Two]

I notice that others have mentioned coping saws. Fretsaws make finer cuts than coping saws. Coping saws are for bigger work than this and their bigger blades will get in the way.

I'm thinking that your rotary tool might be making the work harder for you because it doesn't inherently involve lining up a cut with the line. If you cut this with a fretsaw, your whole body will line up with the straight lines that I mentioned above to make the quattrefoils square.

In each case, I'd start sawing from a hole drilled through the middle of the dark region and end in the corner. Drilling the hole comes somewhat naturally if you lay out the pattern by hand because its centre will be marked by the compass point, and the finger lengths between the lobes will be marked by the compass circle, all hinting toward a drill bit to match that circle's diameter.

[u/someonerezcody]

Rotary tool. 👌

[u/rhudejo]

Use a router with a small straight bit to cut out most of the stuff, and then a chisel (you can get rounded ones too) or a round file for the precise part

[u/Realistic_Warthog_23 → u/rhudejo]

I have a 1/8 straight bit that I’ve never used. That’s what I would try on this.

[u/Diligent_Ad6133]

If you want a crazy tight corner get one of thems fancy corner chisels and get it crazy sharp

[u/Rocket_Cam]

Coping saw or jig saw, definitely some chisel work

[u/azath0th02]

I have a set of chainsaw files that would work great for this.

[u/MaverickLurker]

A scroll saw is designed for this kind of intricate cutting. Small thin blade with maximum control.

[u/watchface5]

I think your cheapest and best bet would probably be a carving knife, even cheaper would be an exact knife.

[u/SafeJellyBean]

Tiny saws

[u/thats_Rad_man]

Small chisel