Tools I used:
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Step 1:
I purchased guitar saddle blanks that measure 3” x 3/4” x 3mm. It was not necessary to cut the length or width, but I had to grind the thickness. The hands that I used for the pattern were about 1.55mm thick. After using the grinder for the bulk of it I sanded to smooth out the ridges that the grinding wheel made until the blank measured about 1.8mm thick.
Step 2:
Next, I used Elmer’s school glue to attach the bone blank to a tongue depressor. This gives rigidity, as well as, more surface to hold onto while working. I made a copy of the original bone hands and transferred the outline to the bone blank.
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Step 3:
Then I used a Dremel with a diamond cutting disc to make release cuts along the edge of the bone. This will allow me to back the saw in and out easier.
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Step 4:
The next step is to saw along the outline using a jeweler’s saw. This takes some getting used to and practice. I broke many blades. Now I know why they sell these blades in 144 packs! The blade that I found to work the best for me was size #1/0. I tried to get as close to the line as possible without cutting off the line. I am actually holding the saw upside down in this picture. It works better if it’s held the correct way.
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