Cut Out the Porch Bracket
For this job, the band saw has certain limitations since it can only cut the outside of the design. To cut the intricate interior pattern, the ideal tool is a scroll saw. First, take the brackets to the drill press and drill holes using a bit the same size as the smallest radius of the design. Once holes are drilled in each of the interior sections of the design, insert the small scroll-saw blade through each hole. Then attach the blade at the top and bottom. When the saw is turned on, the blade moves up and down, allowing the interior portion of the design to be cut out (Image 1). A hand jig-saw could be used for this portion of the project, but a scroll-saw is more accurate -- especially for tight curves. Once the interior cut-outs are done, take the brackets back to the drill-press, where a sanding bit is used to smooth the cut-marks made by the saws (Image 2). Use a wood-rasp to file the tight inside corners of the design smooth (Image 3).