Tips on hand machining with a cold chisel.

[ericc]

I once chiseled a 1" square hardy hole in a stake plate. It took about 3 months. It can be done, but there are few resources on the Internet telling how to do it. It seems that in the old days, most chiseling ("chipping") was done on cast iron, which was substantially softer than the steel you are probably trying to use. From what I read, it is important to hit the correct angle. Too steep, and the chisel digs in. Too shallow and it glances off, and you make no progress. Try to keep the chip going, and keep it small and thin. Sharpen the chisel as soon as it gets dull, otherwise you are wasting time dinging metal. Also, if you are hitting the chisel hard enough, it is going to produce a lot of noise. Unless you can control the noise, it will make neighbors mad. Hearing protection is a must. Unless the slot is small, I would recommend doing it hot, or making a tiny belt sander that uses 1/2" belts. This will be a lot easier. This kind of hammering can lead to repetitive motion injuries. Do not do it in long stretches, else you will become incapacitated for weeks. Do a little every now and then, and it will give you plenty of time to think about it. After a few weeks of pounding, you will want to check out an Alec Steele video and do it hot.

 

[Koi]

So you use a Dremel as a makeshift mill

 

[Koi]

I once chiseled a 1" square hardy hole in a stake plate. It took about 3 months. It can be done, but there are few resources on the Internet telling how to do it. It seems that in the old days, most chiseling ("chipping") was done on cast iron, which was substantially softer than the steel you are probably trying to use. From what I read, it is important to hit the correct angle. Too steep, and the chisel digs in. Too shallow and it glances off, and you make no progress. Try to keep the chip going, and keep it small and thin. Sharpen the chisel as soon as it gets dull, otherwise you are wasting time dinging metal. Also, if you are hitting the chisel hard enough, it is going to produce a lot of noise. Unless you can control the noise, it will make neighbors mad. Hearing protection is a must. Unless the slot is small, I would recommend doing it hot, or making a tiny belt sander that uses 1/2" belts. This will be a lot easier. This kind of hammering can lead to repetitive motion injuries. Do not do it in long stretches, else you will become incapacitated for weeks. Do a little every now and then, and it will give you plenty of time to think about it. After a few weeks of pounding, you will want to check out an Alec Steele video and do it hot.

This kind if chisel?

 

[Koi]

Will a cold chisel make a cleaner cut or a wood chisel assuming they have the same hardness to cut steel but with the difference of the shape ending with different result.

 

[Bob Korves]

Will a cold chisel make a cleaner cut or a wood chisel assuming they have the same hardness to cut steel but with the difference of the shape ending with different result.

A wood chisel is made for cutting wood. It will be destroyed trying to use it to make significant cuts in steel. The very hard and thin metal and shallow included angles on a wood chisel are going to crumble in use. The handle is not intended for the heavy blows needed to cut steel. You do not need to believe us, Koi, get one and give it a try. Let us know how it works out.

 

[Koi]

A wood chisel is made for cutting wood. It will be destroyed trying to use it to make significant cuts in steel. The very hard and thin metal and shallow included angles on a wood chisel are going to crumble in use. The handle is not intended for the heavy blows needed to cut steel. You do not need to believe us, Koi, get one and give it a try. Let us know how it works out.

Can I make a cold chisel to have a flat under until where my hands grip. Will that improve the cut.I'm assuming it will focus all the hammering force in the same direction I hit unlike a commercial made Cold chisel.

 

[francist]

Suitably (or perhaps frustratingly, depending on your point of view) is this excerpt from The Starrett Book for Machinists' Apprentices, a truly wonderful book that I forget to refer to as often as I would like. Alas, no numbers provided for angles of attack, and the illustration makes the process look oh so casual. Different times, to be sure.

-frank

 

[Bob Korves]

I already told you that one. Cape chisel.

 

[ericc]

Koi, use the cold chisel. The wood chisel's edge will break if you use it on steel. But maybe you should try it. I did. Best to do it with a cheap garage sale one, since you will ruin it. Wear safety glasses. You can often find cold chisel suitable for your use for a dollar or less at a garage sale. Sharpen several, and feel how they wear. How long have you actually been working on the slot (as opposed to planning, discussing and shopping)?

 

[Cooter Brown]