Chopping it up:
If you know someone with a high performance circular table saw you might want to give that a go, but forget dad's Black & Decker hand tools. This is the first time the well-known motto comes alive. "Your work is only as good as your tools". I tried being a cheapo in every step, but when you are trying to saw through a copper bar with those dimensions, you better get a high quality handsaw from your local specialized
hardware store. I say specialized because most tools needed don't cost that much, but simply can't be found at the DIY warehouses we all know. Besides, you will get to know and appreciate the professional advice given at such hardware stores. What does this get you? Using a crappy handsaw you will be sweating for 1 hour to make 1 section cut. With a HQ handsaw the same work will take you about 15 minutes. It was worth its price of 25$ I’d say.
For my compatriots, open those trusty yellow pages and look for: "3505 Ijzerwaren - Kleinh.". In English that should make something like "Hardware" to find that retail hardware store near you.Introducing the workhorse and its sidekick
Before we go on, we need to talk a bit about how we are going to make channels into the copper ... in a cheap way. We will use nothing more than a cheap bench drill and a Dremel to accomplish that. This is where I have to give the credit to #rotor. He invented this particular method that is so beautiful in its simplicity. Further down i will get into the specifics but it will come down to drilling a bunch of holes in one step and making channels connecting those holes with a Dremel in a second step. You could also use only the Dremel to make the necessary channels, but that will cost you an arm and a leg in Dremel discs and will take a real dremel-ing artist not to make it look really junkyard sloppy. But we aren't in it for the looks, we are after performance, so you decide.
This particular model cost me 50$ new, in one of those lowly DIY warehouses. That was the cheapest I could find, made in China. In my opinion this is one of those tools we can save some money on. The properties that define the bench press' price are: HP of the motor, play free spindle. What this means for the operator is that a cheap one will take more time per hole.
The next tool is also indispensable but can, again, be bought as cheap as possible. Let’s hook up with the vice. This nifty little gadget, for one, will allow us to secure the work piece so we can drill our holes on a stable platform. It cost me about 15$. As you can see in the picture, it can also be used to saw up some ram sinks with that newly acquired handsaw, without cutting up those precious little fingers.
Time for some BluePrints -->>