Working with a Thick Copper Sheet

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Old 09-26-11, 02:16 PM
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Working with a Thick Copper Sheet

Hello,
I have recently been working on a project in school to make a lamp and I have been making a lampshade out of thick, heavy sheet copper.
The problem I am having is that it is a complex shape; I have cut out the majority of it with snips but I am struggling to cut away some of the large excess bits in corners and tight spaces etc. I have tried using a dremel tool but to no avail. I began filing them with a large file and it seems to work however it is taking a long time. Can anyone suggest some better tools/ techniques to help me?
Thankyou, SchoolTech
 
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Old 09-26-11, 03:22 PM
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Router table with a milling bit in the router might work.
 
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Old 09-26-11, 05:54 PM
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I'm surprised a dremel wouldn't work. Of course the metal bits and such would probably plug quickly...but a fiber reinforced wheel should work fine. I've used them to cut copper pipe and tubing.
 
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Old 09-26-11, 06:57 PM
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I use a high speed cutter bit in my Dremel with good results. My favorite on copper and soft aluminum is the Dremel #115 bit. The diameter is a bit large for detailed work but it's good for rough shaping. The #193 bit is much smaller diameter for smaller details but it's surface speed is much slower than the #115 so it cuts slower (not always a bad thing when doing detail work).

You can also try a very fine bladed saw
 
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Old 09-26-11, 08:41 PM
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You can also try a very fine bladed saw
Maybe a jeweler's saw?

............
 
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Old 10-01-11, 06:34 PM
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how about a 4" grinder with a cut off disc?
 
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Old 10-01-11, 06:51 PM
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A Dremel Tool does not have much power and is only suitable for very light work.
It can not spin any kind of abrasive or cutter with enough power to remove large amounts of material.

A 4" grinder would do it if the disks are the right size, or a die grinder which is like a Dremel on steroids.
 
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Old 10-27-11, 09:18 PM
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Google, harbor freight and go to their web sight. They have an air nibbler used to cut sheet metal for auto body repair. They have 2 listed and both cost $29.99 each. If it will cut steel it should cut copper. You'll need an air supply to run it.
 
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