[How do I?] Choosing the right steel for the job.

Try looking at Metals Supermarket: http://www.metalsupermarkets.com/MSC-Home.aspx I've found odd sizes, pieces, and alloys that others haven't carried.

On a side note, the Harbor Freight band saws are pretty inexpensive, especially with one of their 20% off coupons and maybe used ones on Craigs list for even less. Just something to consider. :)

-Ron
--here is one more co.. in seattle they sell all kinds of metal in small quantities--they are cvalled ''metal shorts''http://www.google.com/url?sa=t&rct=j&q=metal%20shorts&source=web&cd=1&sqi=2&ved=0CDsQFjAA&url=http%3A%2F%2Fmetalshorts.com%2F&ei=adOhT5OJLq_XiAL_3OmYBw&usg=AFQjCNFCTIZMX7JIT4ps8ASZUfWSDLyiIw--hope this helps shorten the journey. re steve in mt.
 
I would use old lawnmower blades. I have seen this done for the exact project you are working on, on one of the PBS woodworking shows. Heat the blade to anneal , file in your shape and then harden to the temper you want.


Where you are located lawnmower blades may be at a premium due to lack of grass.
 
Jim that sounds about excellent! In fact I am going to start looking for some lawn mower blades for my own projects.

Steve
 
Use 5160 for this. You can get it from admerial steel. Look under their knife steel. 5160 is easy to work with and very forgiving. It is also fairly cheap. To heat treat. Bring the metal up in tempature to the point where it is non magnetic and let it air cool to a black heat 3 times. This will normalize the steel and reduce the chance for warpage. Then bring it to non magnetic one last time and quickly quench it in peanut oil that has been Pre heated a bit. Let the part cool. Then temper in a oven at 350 degrees for 1 hour to get a 58-60 Rockwell hardness. Hope this helps
 
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