Post #456924 by TikiMango on Thu, May 28, 2009 1:47 PM

TbT, I just started with the bone myself, so I am not sure I'm the one that you should be asking. I'd hate to teach you inefficient work flow and bad habits, but...

I don't have any images of my process (maybe next one), but I'll try to explain things. I first start by cutting a piece of bone off the tubular shank. I don't have power tools for this, I use a manual Japanese pull-saw. I then go over to the bench grinder and try to form the "C" shaped fragment into a flat work piece. This generates the most smell and dust, and it is very easy to burn/scorch the bone, so be careful if you follow this.

Once my piece is relatively flat and equal thickness (or not), I sketch the design with a pigment pen. Pencil doesn't work for me. Usually I like my pendants to be thicker at the top, I reason that the area around the lanyard should be the strongest area.

After the design is roughed-in, it's back to the pull-saw to cut away the majority of waste material that isn't part of the pendant. I should use a vice or something, but I don't. Then I use the bench grinder again to shape the outside of the pendant, smooth down all the sharp edges I don't want. I think if you had a coping saw and were good at it, this step would go much quicker.

I then use my Dremel-like tool with an 1/8" round burr to create all the through-holes. It removes material very quickly, and can jump around if you try to take too much, or are pushin' when you should be draggin' (or vice versa). I have mine plugged into a speed controller so I have more control. When I have a large opening, I'll create several holes, then join them to form the shape I want.

After that, there's a lot of bit changes... smaller burrs, different shapes, grinding and sanding bits. I think I need a micro-chuck to save some time looking for that stupid tool wrench. Once your design is done, it's all finish work- sanding and more sanding (and filing now), till everything is smooth and the surfaces have decent (your call) transitions. I hit things with a small buffing wheel, again, it's too easy to burn the bone at this step... and that's it in a nutshell.

I hope those doing it longer than me (the experts) chime-in and provide proper advice. :D