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About the Author

!

Born in Budapest, Hungary, scroll saw guru Frank Pozsgai attributes

his love for wood cutting to his early days in concentration and "displaced persons' camps in Germany. Awaiting liberation, he found solace and amusement in creating some artistic or usable object out of wood whenever he could find a scrap.

Later on, while attending college in Los Angeles, Frank excelled in art, especially drawing and painting. While he went on to pursue a career in industria] engineering and facilities engineering management, he never lost his love for wood and art.

Finally, in 1989, Frank found himself laid up with back problems. As part of his "Boredom Therapy" he purchased an inexpensive 15" scroll saw. Suddenly, his artistic talents and industrial engineering background started paying dividends! Frank set to work, retrofitting the machine with numerous custom-designed accessories to make it more user friendly. He also began creating three-dimensional patterns, and finally) he a~ded the idea of carving his 3-D 'figures to give them greater realism and personality. Soon he was being urged by other saw users to go into mass-production of his accessories and designs, -

Because of his success, Frank has been featured in Woodworker's Business News, and presently teaches weekly classes and workshops in the Portland, Oregon area. He continues to work with users, manufacturers and retail stores. Frank's "how-to" videos have enjoyed great success, His company) Pozsgai's Designs; is dedicated to "Removing Obstacles to Success," and he works hard to develop unique state-of the-art products and strong technical support for customers.

Frank's previous four books, The Scroll Saw Book, Scroll Saw Pictures, A Scroll Saw Christmas} and54 3-D Scroll Saw Patterns, have received critical acclaim. These two new books- should please those who wish to share in his arts & crafts talent.

FraDk Pozsgai lives in Aloha, Oregon, where he runs his workshop & business. He can be contacted at: 19390 S.W. Murphy, Aloha, OR 97007- 4428 or calling @ 1-800-872-2803.

Dedication

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Published by' Sehif[~r PLlbli~hii'lg, U(IJ, ,~i38(!i 1,.JJI.\I1!~' \k;ll~!;' R-oe!d Ajg)~I1L, ,RA. lElfnn

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In &!lWpe:. SoMwr iboob, 'ffifB cli;ttioLJtEd b~' Glill5hwood &ol!:~ is ,~rI~l:',;I.iWtlnWi: K.f;w C'ii.airtlk1M

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IJ.1e are .m...ays'IQoiJling JOT people t.n 'Mit.e boiJikg, 0111 I!l~ aM r.eiatErl subjects, 1f. !{O'U 'have an idea IkHr <]. 000& please oon1act U~ , .. t !he ft.t:gien, i?A. address. ~u may wrote r,m .. f[€8 ;ca~2Ih:g.

Contents

Acknowledgments " 111 ••••••••• 111 , ••••••••••• " ~ 'II~If.' 4

• Special B1ade and Cutting Hints , 5

• The Right Blade for the Right Job 5

• Scroll Saw Blade Selection Chart 6

• Sizing, Copying, & Transferring the Pattern 8

Introduction 4 111 ,,, ,1 •••• 4

Instructions & Tips ., " "" , ,.; HIIIt1111 .,.. 5

• Selection of Materials ·-~ .......... '!'!T'!!''I'!'!'('' •• '.iI'ff!l .. fU'~II ....... tt!l''I ••• f ........ ti6 ... ~ ...... lt ..... 1I'III8

• Scroll Saw Cutting Preparation 10

...

41 Maintenance & Upkeep of your Scroll Saw 10

• Safety Procedures 10

General Characteristic and Manufacturing Process

of Scroll SawBlades .. iliil.iiil.II •• ,jIjI liI i ~." + 4 11

Pozsgai's Designs General Guide to Blade Speed (SPM 11

The Project .. t ••• t " ~ •• !f.f!:4 !f 'I.I It 1' ~ 12

• Sawing out the Patterns __ _ 12

• Finishing the Cutouts 13

The GaUe:ry ' "' ' .• ,'tt •••• ,,"'''"P .. 4! I' IJ !Ii I !I ••••••• ~ •• ~.tl1i •• lS

Ornamental Patterns I!.oIII u' III1 ~ , t,,"' .. , 17

Sample Base Moanting Patterns 46

r

Alternative Router Bits and Profiles 48

Acknowledgments

Many outstanding cornpanieacombined efforts to assist Pozsgai's Designs in making this book possible. Questions about equipment and accessories maybe directed to; ·Woodcrafters, Portland, Oregon; 'Penn State Industries, Philadelphia, Pennsylvania; -The Olson Saw Co., Bethel, Connecticut; -Tbe Woodworking Store, Hickey. North Carolina; 'Porter Cable Delta Machinery, Jackson, 'Iennessee; -Wildwood Designs, Inc. Richland Center, Wisconsin; -Melset Hardware Specialties, Mound, Minnesota; -Amana Tool Corp, Farmingdale, New York.

My thanks goes out to all these fine companies and their l1elpful people.

"

I:

Introduction

Incredible Stackabics was designed for the both the beginning and the advanced sawyer. The ornAmental patterns are at the same time simple enough for everyone and. filled with enough potential to i;hal1eng~. the most skilled scroll sawyer. All the patterns are original size and are drawn in outline. However your craft is oll,t,.y limited by your imagination-in how you choose to display them. One can see the numerous ways items can be given used creatively by turning to the Gallery section in this book. Even more, the patterns can also be used to create puzzles for the kids or grandklds ... a great learning tool about various animals.

For the sake of all sawyer's we will be adding to any of our future books a complete scroll saw blades selection chart, as well as a general (SPM) blade guide, This information will be very beneficial in improving your knowledge with respect to proper blade election.

Once again 1 would appreciate. hearing from. you about your success with these projects. And please send me any suggestions or requests for future pattern designs, "Happy curtin' to yal"

4

I 11 C' 1l- ructi 0 'if'iiS &" Ti ps .r .':)'Il..l .. \..-"l·J!.l ex . •.....

• ' The blade ~1DU use '5.1illl~ll,j ]mve :i rllLh~iJJl1il.l!ril1 ofthmi:: teeth per lnull~lI'ird thickness .

• ' Cri~i~rlg !ip<;:cdis nUl)' be i.llr.r,~ed ~Llg bind;:::!; wi rei) tu.rger teeth, bu • • :lli~ wj~l. i'l':'S'Um: ~n II. rim:i~hDrl ~dge 1:1li:!I~ WTii'l be mL~§b~J,

.' r'iflc:r (:;r;rnootocr) UI~!'i. m~ ~t~ :i'idr:i~'fccll with bhld\c~ W.lto ititl\te ~e~~il p!1' nliclr. !!Uld sLuw.tJ" ';;1oJ~'I'ifLg ~"P~~'

., Whr.:fl ;::l!IU i~ :mfl ]ml~eri~JJ:;, use <'I blade ~!o'itb I;)rg.<e ~eeLtl. Hf.!~ d nm~~ii.lls..li.te cut best 1\1[tb a b~ild'e w.i~]~ tine. ~ee.tL,

" If ~,\W bums ur !iiel1i3 mf!'i~:ti..;11 ~~'11.::~ ceu ill.£. c:il:I;~· ~~"'i" ~Ilo:;: e~il!;I,ill:S ~11!i;"::dll):r i~ictll~ !'lie l)la~ SiM: (~Md'~ 'WiU'i ~~(j.J~ ~oon\),

•. [me ::1(Ert]j[iA)J1fl~ ~~p ~o [cd~l;re QF elli:nn.itl;fi.e L.'I.rrBing.. 1 J~in~.l" ck:!!Ir :;M :pi'IA;:~~if!:S. ififAl 1 c 1~'IfC:!loP"2 i~~' wC)c:d .0]' ~~imJ~L~ rj8tCC tire .lIp:: !.)'!.'I;:r m II.m'*r tile ~1(itt!Cm I'm 3:b~ut t\f.i CI;J.t. The tape lubricates ~ lae 'bl:lde; rre,'o[)ling Imrll illS- 'YoLI \l'rm'~. bl:::l.ie\'c; Y'f.'l!lIr ·~C~ at the a-eSi.1lt!'l~ Usc this method 'WiiHl n'lllrlird .& .:;:ro~ic woods..

!'lIP; ~1.J!1'1~ hc;)rr~ ~\TM ~""'IIfJl~ ~-er:r c:; <i!j, p;!ul~tll~lIraJ" IIlila~ il'h~ li~lf s,::'I'OJi I\~j.;j"~ )'0111 sac en 1'his !,(1m. ll~' 8..11"111:)1 deDJI' pat:.k~n~ tope. ibero:re Cl1ttim.g.. it fu pn~iL'I!l ~C! l'0lfU.cr. or !3'.Iitll:ill!!l[~ !b~ i:!L!illiiil'lQ,..

~ tun :i!.ll! lhe L">:!'iI.!I~ tIf ...... I;! <l,:1!lls wi~h ~hl;! S;lIi['1l;!' M1i.;l~ ;m,d ~I'el)d i ... t'hi< plece of.P'tlr.PI~ Ihe-.u'll 1'1.000, 1it~ eop 'tine · ..... n s oone '[I.1ict~Q1111ih~ tape n'!1d !bi:M'.3 ~1"'lcb bll.mlfiig. 'Th.~ ooi!oi1~ Q[:!c was dono .,...ll~ !m(; t::'lllX' ln .p-i:HI!:l,

CJi}I:Jli!"~ij' W !il.!rn!~iI'Oil~ opi!~iQi1~, jtl~~: like [[~!1l~! it'~ ~tli!! ei'id feSI;J~[ ot wllk1[ one ~cl1:!.;!~ 'Willh til;;: ®::I'OU S~ tiltH: COUll!'5-- I :;!ItT! ~'G:pi;!il!tG:~I~ &'&ked! "wtl,.,'it bJacl~ stLml~d. I us;e.,?'" 'Jh~P$ :,'i1"C roo, !iIljflJB1' ~1::!.ri~h~C;5. 'tQ' OO[~[.;r.e!' M .gili/Ill.;1I [;i~~. ~~~VIOlt' to ~1l:'r:I: .q~II!!!'l~'CYJl.!: T.I~. ~w u~lf wlir8ltr{!T ut\ an B;C1i]ib~lr.:I1. Hegner, IDclt:l~ R'BI H~k, -IlT an hnport, is.not the most ill[l-l~O[~~l'[t ·!fi!';t(if. 'Most s:;.ws esn be; m:;.dl1·!O dIo It g(JoJ}lj job. More ~rnpi,Jr~~~t 'ITD~~iJ1!'1 am Urfi b~ad~ k:]1Aia;rl;. UtI! r~Qd. mt·e. ~1'01.I1T sensjtivHy, ~he S:pll"OO (SP.M}, .njl~ the ~.rpe of ma1~iILI. you ase !;"1[HUIl~.

TIir:~i!: ~irig sB:id, tn'{: blade is ~me singi.;:' 1iIl~~: impart,mt enmpon e nt Oof a scroll :5<1 Iv! Lf Ii~ r igh t Ibl m cl~ is not use dl fur t m.e j ob I' t he D'CSI.I.l1::;. '\filIilJ'1 IJ e '\'i!tl J lit alll yl ill I [~ Arlll:l t ~teT-e: ·llire ~!J m i!ur Y 'I\J IT i <I b~ es r lu t yo'lII need ~CI ]lliVC ::'I. '!lrIlii~~.~' of O'l~(ks ;:J .. .j)~Ii1bl.e Ior J!oor 'SiJW, Re[[~ei'l1l· bell' Uwlt ene or ~.WD corunaon blades wii~ nol be ·elJ!:rngi~ fur ~I I1t'!NI.Qi1, much Ira: t~!t 'l(:(;t!'Jfnpl i:s!tot:d :h;r(!~ICi",

("h'lJlJl!i~IJg the ';;IJIF'I!t;~ bl.il~ ~j~. i)ocli Woih 8~'yle :!)Clr i he il1m~r[.ilU LIl b~ ~ l is _he: key fi1t~Or fot aC(:lilint1e. and sinoolil tlCJ"Co11 Sa'l,'1TjD~. [J it is. dune rigor. 'iJiLo:.'! cun eLiJtdn:;]~e {lit' red~ce Ihe 'CO'Jl~tLm~ pl.'Ci!hr<!;!Jl] ef ~'Illd[[igt

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('u1 tli~ .I~tre[[) ~l[TIi.ght IlkJlg Ute bnse, Tlti5. [is. importnnt ror IProp~l lIitt:1i:J1i'£:lit 'witl~ ul!lt.: 'J'IliflflL3. H LIm; OO'Ufm'l of uiltC (flAH~I~ il> ~h';!i.i@l~, It can bi: !;Iid. OI.!!l,;lill!l;l, I,I~ ld',;li1lI~I' ~d,u.;,; ~)f I~II~ '!Jo'oU!;ld ~I~ W"'-'; rl.:rl~ ;1 ~;rlll ~iml! ·rr::r~ jr:lili1i~l!!1: 11!~~r,

• "Jl!r-;ruIil:s'.furrJiull; UI~ 19"tblMEi Iilo .ill~ '~~rl .. J?':i£!i."C:', 'fbr;::~'t are ~r;::"'t':ml p.mdHe~s O:li Ihe 'lil;nJ~I::~ ODe can cheese h) adheil~ 1]W. PfI.~~J\l1 ro ~~~ ~rk pleee, Tiley bLt:b.t~~e:: Ghli~ S11e'~ ~ AW:,rlj, 3M's Sr;oT~hlJJt;)lnd'u lSpir.ilY ,i!I=Hlo!;~jV';;. HI bbii! r ceme I~'i. ,.: t~. M~'ke Slj 1:(; i II ~~ erlr~ I h~ 1',l}poomolWlbl~ 0: I em po rol! flJ 'bOfH] hems,

TIw 'r,rtO'O'l1l1}!;! 'paH.;]!itJiIS m~ br: s~d frulH ~ wid~ '!};:!irl.e~~ of OJ'· feli'>$.n[ Il~iJiLf}'d~I~, & diflf!2J1er~t ~1l~d::IHss-Ll~~ dLoice:s:ail'r:'~ IltiI-el), YQIu_rs, 1T r: t,;);i'Jge C:;]g-i it:"le!'U,d~ wood 'liI'OO~iCi!S, pl:ii~.Je, {iii' ~V~l~ 1i!~IlI~i'!Il!'t.

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Ttl l"'01l'1l'M! IWI) pieces cl' \'irolll1li 1~t'~~r I !JI~e (!lc!!I!!' p. .. dl;i'J\I~ '!:i!~. ,';15 rncmloned (',&riElr. this has tbe ad'd.-.xJ b~~1t of l~lbr~ljD.g ih~ tilM!..::.ri~ i~ C11t!i. k~llillB it [l'!:IliIl 'lxJl1Ililli1lj tl~ II111WdL

I !u,!)' ;h~l,! 1l1~ ~rIYl!lhL1111~ 11TH,.:! ~linlI;l'II!o;i[]I~, 'I'lIi1)) i~lll.ipil tl~iJ,:k!ll~. Th~~ .r~ J/'~" tl~iGI-l;.

.. '!i'll'iI1!; ~tit! 1II'!)!i1o:" M.,l..., 'p~rioJJk:~lI)l, TIl is will help ! he Si(l'~" ~~d~ eiJ$j~ Q1.reL' Ih!!. W(lt'k ~,,'Ib!.e fiJJ m'I:~~r ,rol~trD!.

iFl:Ir ~j:Ji~ Ii'rT4~;:! T .!II11 'II!';ing n ]1i::I~i1 P·WSt;mll :.liij.W. ~~ \';,',,,,.. !&le ·nev.'e~JI ;lYailatLe and I:; ullK: 1:00::;[ ~~-:rl1~nd~ ~rol~ ~aw 00 ih~ mnut~~, ~t lsns f'nulfierOLl:> !l'e-.!il ures, ill~I_ldiI12 a fJ~ll. IlI'i\l~, tlll"lt irlii'kii ;!!11!1(ri;1 "il:!r3~kit'1 rrc~.

.. L!]'III~I fll~ itaihll!'. ::Iindi, 1~l1g:3 sq~J;!Olre_ check to see iJ the blade i~ Jlt 2111 ,mgie of 00 ode::llIK~"i OF ~ndL'l.:ubr so tile SilW table,

'fubl~ can he: reSldJI~ .fIdJLtiiL'f,!lI 00 '~!A[Jj]1hli k:vd,

~ 5 e!!e eI: I:he bl:!!f~~. ll~nlernbi;:r, 1iI!'l~ ·r.I~G ri;h l hl.:l~ fi;l1.' thl;: light ill ~t~ i. lal. Rlr £(1Ii[i!l811i~, check out ~~ hl~ct!e U~ {}uiill!:l inc CI1i1i[ ~I~ this I!iOO~_

'rI!~ hllaillc ~rifJlt rid! rll:i!i~xJd Pl1lj~all~ ~Ei~ {)i~ IPGiT oW:Jo'Ilblo!' I~;";:':ri!ll w(1~IL. H ,~I~n; o!;l~i~ ;';:';i!<il)! !j!il!~ ~1~!1~- 9IXI!.:;r,

~ 01t1!~k '1llII1'rli!1l ~l;liIli!iWfl~ The .I'-tUlI~ IjJf Thumb; WLlelJ ].'00 (MJ~h the blade .fru.li[ 1.0 mlci 'w!l~b YULlJ ~J~lIlirib, }'Uu sJloWd ~i. i.II ViS·' do:::{)(~~li;;}.n, ~~J~mber pl:riooil;i!U)f bl':loll;ir: ~r:!1t.ktjb .i!.;jjw~m~nl !~ <l Ult~-

~ 1)1.:C'.ul~ '!.!in f~ !!,;i,iildh!,g SIJie!::t1- Est!l'biisll ~'I~ proper "S.·f.l\1," s,troJ:;es ~~ Mil'~L~e.. ~t;~' the p:rQjlX~- CI~e>tk ,,"'ut ~tt~ G>!"i IteF,ll (i~drle ~Q Clfi~~]I'1~ 5L~cd Ii'oJ the !n[l,tet'iQ~ YO:!l· 11~W. s:e-llfct~1. 'l,l~!l1Mi!gI'!N i 1;0 ! ~;J;cI the :~-'~f:tiQ!1 ~"'JC:ltailflji:ng ~I) sp(:~i;j!1 L1br,l~ ;;11~(I c.uU illltS hini~ ::!IS 'WC!~ as the: ri.81~t blade' r'il:!l~ the r:i's,htjoo.. 1h:!¥r.li~!H3' sa .... oyen: till!: w.ill i nl.·I)' be: hc:lpfili.

~ [hm'.: I,K! :IIfnll;dI,. l~:lm not ro be 8i'fllkl of the !-iNiJ~~ 'SflW blade and · .... 'i:!~k ·~rom. H1:" 10 J.'" ii!I"iJ!Imd ill,:: scroll saw bfadc whi lc yot!I arc !f.uttiJI\g, ],I~~ iii JHi:W: .ilnpo.rTl:::mt;. and wilU rnu:ke -!l RIG differenoa on yrnL~' [il1isl~ prurluet,

Ali scroll s,o,w,; ~uliFt: 'jj~riooi;;; ~!'!<!IVll~lii~jj~~ Th~!> intllijjd~

~ O~O/ISiJig (riM ol)j][l~ of ri..ui: ibol- ~\ft!iI"J SI)·1:5 hours {It HIITwinlj: 'I'Iil~J,::, No~e; On d~. Ile'!.--\' d~ltll'I\~ ~I(I~! 'Ii(iJi}e: no -ctloioe but 10 oil.

~ Cltei{:k~l1g :ro~1 r motor l);r~l:'lhs ~fi(K9ir;;j.lly i1IlH~ ~lflCii!S them

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~ Ck::JImi I~ ill"!:- ~rnll:i3W [IC~iod i!:'::lUly. (,-'SpJctiill~y ::Iil:OUm:J &l1c rJitDDCir &. c:l!xtr.,{ll1i1! COI~tml~. Cmmpre!';:;;oo 8Ur .... ~rll:~ 'i!.'C:di fm- ~hi~ ~215_k

R,*mJ. }'Or1r .;)1.'tl;I~~L~· Q~r;),trlig ~"~Ii~If! l ls ~sl':~l1ti~1 fm" all ~1\Yf!:r~, Oi1":1ie iJ!.,giill~~ Uj~ ~~~ 111~'!. '!:I'llly enjo)o' )/Qii r :5C"1.\!!11 ~fI'I1.'"

• Hardness; -Style

(skip tooth): -Dimenslon (tooth cut): • Bell cI Test:

Carbon: .070%-.079% Silicone: 0.10%-.030%

Manganese: 0.30%-0.70% Chromium; 0.10% RC53·55

15.0 TPI

.001 "/.008"

The Reverse Thoth Fret saw blade must be able to revolve around a 36Q11 pin without fracturing. Then the blade must return to its relaxed state and remain bent,

All the carbon steel wire product produced in the U.S. today either comes from all open hearth or electric (\!fIUlCCS. The typical USA Acid Bessemer Process is what produces the superior quality grades bf steel. Virtually all scroll saw and similar blades are manufactured from a non-resulphurized high cal' bon steel.

4 Scroll Blades Regular Style Teeth (5"or6"): Blades are notched & set. 4 Skip Tooth Fret Saw Blades (5"): Blades are milled with no set

• Reverse Skip Thoth Saw Blades (5"): Blades are milled with no set.

• Double Tooth Fret Saw Blades (5")-Blades are milled with no set.

• Metal Cutting Saw Blades (5"): Blades are milled with no set.

• Spiral Saw Blades (Y'): Blades are milled with no set.

• PGT Saw Blades (5"): Blades are precision ground with no set.

• Double Tooth POT Saw Blades (5"): Blades are precision ground with no set.

• Thick wood-Saw Blades (5"): Blades are notched and set.

Note: for the experts out there NOTCHED BLADES are extremely sharp and can be equal 10 a milled or precision ground tooth blade.

Pozsgai's Designs' General Guide to Cutting Speed (SPM)

APPLICA.TION

SPEED (SPM)

High speed quickly & easily cuts pines. balsa wood, bass wood, plywood, cedar) fir and others

1600·2000

For making intricate cuts on cherry, walnut, oak, teak, ash, maple, purple heart, rosewood and others without burning wood. With stock that is 3/4" & above use lhe 3M tape trick.

1400-2000

Slow speed keeps blades cool to minimize breakage. Can cut brass, copper, aluminum, soft 16 to 20 gauge low carbine steel sheet stock and others.

400-700

Slow speed helps to prevent melting of some cast acrylic, ASB, lexan & Plexiglas. Note; An extruded acrylic can be cut easily at 1500· 1700SPM

300·1000

11

The Project

~ OS" i"I ~ E"a II:;, b~ i Il bJ.' ..:I rH I in • .fJ 1;1111' t'l i>!! I!~, !I'I ru e, n tl d o LIt ... r 31 reas dUll can b e I:mer: !l"lJrrn ... "Il w,itl~.£I drill pl;;::S

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!For ~'I~[~jr~ ~ II~ ::Ii 220 g_rjl ~cdfJ~!ii\'L! pnd, I rcmose 111m b.?KI'k ",mil fIJ11;! 11'11:. pud 111 IlifIlf, !Bf.:l1~eell lfini!iLl i;1Ji]~ ~. ~I~ i.~ .:!!Ui tri~. pad.

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~ Iti:!~TJ~J."!;I;'.~ ~Ol" M:l.gljllir~. PI:n0:l n magnet alii ~'Il~ hac].;: 31nd ~1"011I have fiOOllCth~I~8 b!3:31'Ll~i6~11'~o .tm~d :!IIil ~]mse ilnpol.tM!ru!: messages :!100 Inedoori:~

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'.' [Jfi~e;tllli.'{i~. 'fhi::5. i::5. done by :sJn~p.l'y add inS.ti! ooc:kiJ~g &: Irnme,

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Ornamen.tal Patterns

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Sample Base Mounting Patterns

Thevarious mounting bases are designed to give YDU an option and style [:0 choose fro:moor your pr-ojeci. Merely enlarge them to )''OU[ desired needs. Remember to mix thevarious patterns with different woods 10 complement }'Q!ur art when using a base to meunt 011.

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Ogoo Fillet Bits

47

Alternative Router Bits and Profiles

Clue Box Bits

Co~ & Bead Bits

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M:OREiSCHI

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