Medieval adventures


It is really hard to work with a 4×8 sheet of metal. We always end up cutting that into smaller pieces that we can then manage with a throat-less shear. Bimetal blades are super tough and worth the money. Brand name blades tend to be of better quality and last longer. I guess it depends on how often you snap your blades as to what quality you purchase.

Jigsaws are a great tool for cutting out rough shapes from big sheets of metal. The main problem with them is that they tend to ‘wander’ off the cut lines and leave a rough edge. A throat-less shear is the way to go for precision cutting. My first helmets were made with a jigsaw or reciprocating saw. I use both corded and cordless saws.
Cordless saws are handy because you can’t accidentally cut through the cord and it doesn’t snag on your metal. Be sure to get a model that uses a 20v Lithium battery.
For rough cuts I tend to use a reciprocating saw. Make sure you hold on- these saws are vicious.
A metal chop saw is great for cutting face bars. It is much safer than using a cut off wheel on an angle grinder. It also allows precise cuts at a 90-degree angle.