HowTo request: DIY liners

[pawn]

Hello everyone!

How do you build liners?

I tried to saw 0.3mm, 0.5mm and 0.8mm brass, tried it with different hand and electric saws, tried different dremel bits, grinders and hand files to shape them. I already worked about 12h on two liners and I'm still not finished.

Does it really take that long to make these f***ers or am I doing soemthing wrong?

Next try is a big cylindric carbide burr from knifekits.com to shape them.
Please post tipps and tutorials!

Cheers & thanks in advance
pawn

[enki_ck]

http://forum.multitool.org/index.php/topic,35639.msg679737.html#msg679737

Here's a thread that might interest you.

[pawn]

Thanks for the link! This is helpful for cutting them out.

I have such a saw but it's not easy to cut the brass. I use a fine metal sawblade and the teeth always catch in the material and I have to rip the saw out with force...

How do you do the last step, when you set the precise contour of the liner? With a mill, file, grinder, saw?

Cheers
pawn

[GigaHz]

I used jig saw to rough out the part. Then I used a jewelers saw to get them less than a 1/4 or 1/8 inch. The number of teeth is critical to cut the brass. 3 teeth on the material are required to keep the saw from jamming. The thinner the brass the finer the saw has to be. Also  the slower the cut goes too. Then I used a coarse big file to get them less than a 1/16 or 1/32. I finished with a Swiss needle file set for the weird shaped parts. Then to the 800 grit sandpaper. Ending with 5000 sandpaper. It too me 8 hours to do 3 at .040 inch and 3 at .032 inch. Lots of manual labor and patience is required.

I used this and broke at least 30 blades. It takes a while to find the size that works.
http://www.ebay.com/itm/390499372048? It is poor quality, but works. The blades seem to be from India. The Swiss made blade would be a lot better, I'll bet.ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649