Pancakes and Waffles in Cheesy Sauce

OK Jesse, since you started describing the “why” of angling a
sawcut to make a one-piece shearing die…

As with most processes, the theory, however elegant on paper, ends up
being just the starting point for practical experimentation… blah
blah blah . I use 1/10" grid graph paper and call each tenth a
thousandth, and plot two points . They are separated horizontally by
the width of the sawblade , and vertically by the thickess of steel.
A line connecting them is measured as degrees off vertical to
determine (in theory) the angle of table tilt for sawing that
combination of blade and steel into a die.

I add a degree or two for heat treated dies, because they just don’t
end up being tight enough to cut neatly if I don’t add. Then there
are the minor adjustments made, minus or plus, to add more clearance
for complicated shapes, or lessen it for (blanking) extremely thin
metal, respectively.So, I have about 40 combinations of angle, blade,
and steel . Lot’s of things go into making quality flapjacks.

I guess the waffles will have to wait , but I can say that the waffle
iron die works admirably, though even thin steel waffleates (becomes
enwaffle-ated ?!) at very high pressures, unlike I expected.
Cheesemeister Dar