Treasure Valley Scrollers
Making Your Name Badge with Stack-Angle Cutting
to ¼ inch stock, a light wood & dark wood
Stick, 2 inch Clear Packing Tape
- #61 drill
skip tooth scroll saw blade
stain and lacquer
- Cut desired stock into badges 2 inches wide by 3
¼ to 3 ¾ inches in length depending on the length of the name to be cut.
- Using a glue stick, lightly apply glue to the
pattern and attach the pattern to the piece of wood that will serve as the
- Place this on top of the wood that will serve as
the source of the name to be cut and inserted into the badge. One could use double faced tape to hold
the wood together but this is more of a problem when it comes to removing
the tape from the small pieces of the name. The best thing is to simple hold the
pieces together with packing tape, #4 below.
- Remove a piece of clear 2 inch packing tape that
is twice the length of the badge.
Center it over the stacked pieces of wood and press it against the
pattern. Fold the sides over the
edges and secure the two pieces of wood together.
- With a #61 drill bit in your drill press, make a
single hole in the pattern at a point along the bottom of the name where
two letters come together.
- Attach a #2/0 blade to your scroll saw and using
your protractor, or the scale on your scroll saw, adjust the table to a
1-4º right tilt; the right side of table is down. The specific degree will vary with the
type of woods used and the thickness.
Determine this by a trial cut in stacked samples of the wood you
- Detach the blade from the upper keeper and pass
the blade through the bottom of your piece to be cut. Secure and tension the blade.
- Cut your pattern clockwise moving along the
bottom of the name to the left and then up and over the top moving to the
right. Continue cutting until you
reach the entry hole. Release the
tension and then release the blade to remove the wood.
- Carefully separate the cut name; it will push
out the backside. Remove the
tape. The name cut from the lower
piece of wood will fit into the space cut in the top piece.
Apply wood glue to the edges of the name and press it
into the badge from the backside. It
will be captured by the angle cut.
Depending on the thickness of the wood, the position of capture will
If necessary use your belt sander to remove excess
thickness from the backside of the name or the front side of the badge. Use finishing sandpaper to smooth the
surfaces and roll the edge. If the badge
is thick enough a ¼ round can be placed on the edges with your router. With thinner material a belt sander or
sandpaper can be used
If desirable, stain the piece with a natural stain
and allow it to dry. Natural oil is
probably less desirable because you will be wearing the badge on and against
Spray with 2 or 3 coats of lacquer, sanding with
finishing paper or a microfine sanding sponge between coats.
Mix some epoxy cement and attach a pin clip to the
Congratulates your name badge is ready to wear! ☺