ok so over a year later. I now have all the parts for this saber (well 99.5%..forgot a kill key, the blade, and usb-RICE cable lol) and wanted to start work on the outside of the hilt and the shroud pattern. which I figured awhile back would most likely require a drill press to make it even on both sides of the shroud work. So this whole summer my project has been to get my late-grandfathers old Shopsmith up and running again (was in our garage for 15yrs..) and finally got that working and tested out drilling a few holes in random bits of aluminum and that works. but now i'm alittle stuck on how to do my planned shroud pattern..
My plan was to just drill a bunch of holes going down where the channels will be and then sanding/filing away the 'teeth' that is left behind.
like this:
Attachment 15793
(circles being each drilled hole)
I'm just wondering if you experts out there were tasked with doing a shroud like this how would you go about it?
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