On Monday I picked up a 6×4 bandsaw for a good price, so decided to do a it of last-minute gift making for father's day. I've had some bits of rail lying around for a while waiting for a project, I figured that a slice would make a good bottle opener.

The bandsaw seems well set up and cut nice and square giving a nice event 5mm slice. That was until the blade snapped; too be fair the tooth count was far too high to be cutting the 5in web and I have no idea how old it was to start with.

Unfortunately I couldn't get a new blade same-day anywhere nearby so had to crack out the hacksaw. Luckily the bandsaw had the cut well established square and had just about broken all the way through on the central web. The hacksaw cut didn't take as long as I feared and came out just as square.

After a quick clean up with a flap disc and wire cup brush it was off to the CNC mill for the bottle opener cutout. After a couple of attempts in a scrap of steel to get the shape right I had a geometry that worked well. The Sieg KX3 happily drove a 6mm end mill through it leaving only minimal burrs.

After a final deburr and clean here's the finished article: