03-09-2014, 07:48 AM
I draw out the design on paper that I have marked for the grid of the background tiles, making sure that there are no "impossible cuts" on either. Then I cut the pattern & trace it on to both the background and pattern tiles. For curves, I try to cut out as much of the non-pattern sections as possible (I use triangulation a lot for this) then I cut many straight cuts comb-tooth like (the calculus part - the area under a curve approx. rectangles: http://www.vias.org/calculus/04_integration_01_02.html ) into the curves & tap out the comb teeth. Trial & error to know how deep for each type of tile, and knowing your saw! BTW, I use a very cheapy tile saw, some of the better saws for cutting repetitive straight cuts are actually worse for this type work) cleaning up the cuts is done with "edging" the cut line against the saw blade.
Even angle grinders have a straight cutting edge that you have to still consider (of course, a wet band or ring saw virtually eliminates the "straight cutting edge, and the guys who do opus sectile with water jets....but all of these cutting tools are way above my level of tile work (as I really have only done this for a very few years & a very few pieces per year...the wet saw is the most cost effective for my low level of craft)
Even angle grinders have a straight cutting edge that you have to still consider (of course, a wet band or ring saw virtually eliminates the "straight cutting edge, and the guys who do opus sectile with water jets....but all of these cutting tools are way above my level of tile work (as I really have only done this for a very few years & a very few pieces per year...the wet saw is the most cost effective for my low level of craft)