- Get a jigsaw
- Buy some titanium, make sure to get 6AL-4V (Grade 5). I usualy look on Amazon, Ebay, and at Sackin Metals is where I look. I have cut up to 2mm thick.
- Get a Freud Carbide "thin metal" blade ($10 on Amazon)
- Use some coolant & apply it constantly, you may need a helper for this. I used a water and oil mix, but cutting oil or WD40 might work better.
- Clamp your work (I uses screws and washers to hold mine to my work bench).
- Draw your design or print it out on paper and glue the paper to the Ti (I used spray adhesive).
- Wear ear protection, it will be loud.
- Cut and go slow! You want to keep everything cool otherwise the titanium can work harden and that is bad.
- Clean up your cuts. I used a bench grinder and a flap wheel.
- Feel pretty cool.