[quote author="TomWaterman"]
How did you cut the artists' leaf - a scalpel/steel rule on a smooth surface? This stuff is so fine and I sense a tortmenting time ahead.[/quote]
Place the foil in between two transparent pieces of paper and use brand new razor. This way the edges will be much smoother, with very little chance of ripping.
How did you corrugate and in what patterns - I found a small herb pot with a nice profile, like a triangle wave...about 2mm on each rising/falling edge, any good? I expect I'll rip a bazillion before I get a good one - any tips?
The right way is to use a good, high precision corrugator, with adjustable spacing between gears. You will need to readjust it (quite a torturous process) for different foil thiknesses. The reward--no ripped ribbons at all.
Once I was looking for the gears, and was quoted for high precision custom made ones at about $500 a piece, from different machine shops.
For me much more economical way was just to buy a CNC rotary table, grind cutters, and cut the gears myself.
Oh yeah, I even don't consider start ribboning those things without at least 6 pack of :guinness: :guinness: :guinness:
Also what are the common adv/disadvantages playing with ribbon thickness and material (if any)?
This is hit or miss. Some ribbon mics don't like thinner ribbons at all.
As Rody has already mentioned, because of less resonant modes (better damping) the thinner ones have better top end. In some mics though, they can have noticably higher noise and worse bass response.
[quote author="rodabod"]
...Reslos like thin ribbons. They have a higher output with ~ 1 micron ribbon than they do when they have their original ~ 3 micron ribbons (I have a fresh NOS model to compare).[/quote]
Are you sure the original Reslos had 3um ribbons? Also, they were ribboned with duralum, which after many years most likely got hardened and lost compliance (unless was kept in vacuum).
Theoretically, with proper loading, there should be no difference between 2.5um (not far from 3um, at least to be very noticable) and 1um ribbons output, as below 2.5um the mass of the surrounding air becomes comparable to the mass of the ribbon.