Hi all! I have to make a dozen or so (every few months) straps for dog "collars" (special purpose items that are similar to collars) and muzzles. My biggest struggle so far is getting the holes for the buckle prongs lined up correctly. I need 2mm holes, so a watchband pricking tool is too small and belt punch dies are too big. Here is what I'm using/have tried so far:
1. Hand rotary punch tool. Works fine, but kills my hands after about 8 or 10 punches. I'm also not sure how to sharpen the punch as needed. I would like to consider this my backup or "for emergency use only" tool.
2. I bought this desktop tool: https://www.amazon.com/dp/B08C4WWKN6?psc=1&ref=ppx_yo2ov_dt_b_product_details It's not a bad tool, but I strongly suspect the punches that came with it are cheap. I'm trying to sharpen them with a drill and sandpaper but they only seem to hold the sharpness for 3 or 4 punches. I stuck some Osborne punches in my Amazon wishlist because I read that they are high quality punches. Should I go ahead and buy a couple? I realize I'll need to sharpen them, too, but hope they'll hold the edge longer.
Sort of a tangent, but I suspect that the way I'm clearing the punch is also ruining the edge. As I said, I'm using a 2mm punch. I do punch it into wax frequently to keep it "lubricated", but I still deal with clogs every 4th or 5th punch. I found that the easiest way to clear the punch bit was to gently hammer a #17 wire brad (finish nail) into the end of it, which pushes the plug leather out the - exhaust hole - whatever it's called, haha! But sometimes the plug is so jammed that I have to wiggle the brad around and basically dig a layer out the tip, and I think this might be dulling the punch edge. Is there a better way to clear such tiny punches?
Last question for now: even if I find an easier way to clear the punches and keep them sharp, is it normal to have to clear the plug out every 4 or 5 punches? The way they're designed - and I admit to being completely naive - it seems like the plug should just travel up the punch to the exhaust hole and fall out on it's own as you use it. But instead it just jams up in there before it reaches the hole.
Oh, I guess I should add that I'm working with 3/4 or 6/7 weight veg-tan straps. Should be easy, yes?