Got no computer & laser printer combo? Then you'll be glad you found this topic. I came up with this handy little template system after a few months of laser printing templates on expensive lable paper. Heat buildup and necessary quenching deteriorated the templates during cutting.
The principle in this system is simple: Cut the profile of a pick into a piece of rigid plastic then trace the shape onto steel stock using a popular brand of permanent marker.
With this line established you should be able to efficently and quickly cut a pick closely approximate to real pick dimensions. Items you will need:
[list=]Rigid clear plastic- draftsman triangle
Pick templates or true scale jpgs- this one from Pyro1234321
Permenant markers- fine tip and extra-fine tip
Drill
Hacksaw blades
Hobby knife or Dremel tool (but I recommend the Dremel)
Tiny hand files
Hardwood scraps or dowel[/list]
Procedure:
1. Notch blade ends- This notch helps hold the steel firmly against the template when you trace the line and will allow the steel to pivot if you cut the trace area off-center. Do this first because the template will have to be fine tuned later on.
2. With a straight edge, score a line on the plastic the length of the pick. This is the center line.
3. Flip the plastic over. Center the plastic over the pick to be traced bisecting the pick shaft with the center line. Mark a spot on the center line 3mm from the end of the pick. Now trace the desired pick using the fine point marker.
4. Drill a 3/32" hole on the mark you made in step 3. At high speeds, the plastic will heat up and melt (giving off noxious fumes too), so go slow. Cut a small hardwood peg the size of the dowel hole and no longer than 1/2" and fit it in. It should fit snugly- careful not to crack the plastic.
5. Next, rough cut the main trace area. Starting 1/2" paralell to the marker line you made in step 3, gradually remove stock heading towards the line. DO NOT start grinding ON the line. I used my Dremel with a high-speed cutter bit on slowest speed and finished the shape with tiny hand files constantly checking for symmetry against steel stock. If you file past the trace line your pick will not be symmetrical and you will have to start over.
6. Trace your pick. In the picture example the traced shape is some kind of snake. If you were to make a template for a half diamond rake the line you want to copy for your template would be the diamond side -in other words, you only have to trace one side of the pick in your template- the side that comes into contact with the key pins.
7. Cut the pick. Allowing a 1mm gap on either side of the trace line is a good enough estimate to know your pick is the desired shaft width.
I was able to cut 3 picks in 30 mins roughly shaped and another 15 minutes to finely sand and finish.
The possibilities are endless as long as you have flat-scanned images of picks or any 2-dimensional line.
Good Luck!!
PM
If it ain't broke.....pull it down and see how it works anyway!