John suggested I post this jig in "Special Tools" so here it is. Its just two pieces of wood joined by two hinges (?) and two brackets* to hold the Dremel. The cut off whell is a diamond coated 1.5" one. The bottle rests between two pieces of metal glued to the wood and the clamp at the right hand side holds everything on the table and functions as an end stop for the bottle, sort of.

I thought it helps to wrap cellotape around the bottle neck to prevent from too much chipping but it is still necessary to take lots of time and dont rush it - I need about 5 minutes for one cut - turning the bottle all the time and taking it very slowly with some nice laidback music in the background. If I press down too hard little pieces of glass are coming off which results in awful lot of grinding afterwards.

*can be found in hardware stores, used to fix water pipes onto walls

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Replies to This Discussion

Super, thanks.  Anyone have a jig for cutting them on a small tile saw?

Jan:

This is a fantastic idea!  Thank you for sharing it, and I hope you don't mind me sharing it on a post on my site (with credit given to you, of course)?

Jess Allred ---- http://totalrojoguitars.blogspot.com/

Jess, no probs, I'll be honoured! :-)

I'm not being critical of your jig, I'm just having trouble visualizing how it works.

Are the clamps attached to the shorter hinged board to rotate the dremel into the bottle?  It looks like the ears of the clamps would jam on the longer board.

Is it necessary to use the metal angle bar or can wood be used to hold the bottle.

I like the idea of it all.  Thanks for sharing.

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