To be definite, let's say we're working with 1/16" styrene rod. Usually I'll have drilled the end of the rod first with something around a #74 or #75 drill to a depth of about 1/8"-1/4" to get a piece of "tubing". The ultimate goal is a thin slice roughly .016" - .020" thick (1/64" -1/50") to be used to simulate a collar at the bottom of a shaft which is itself made from .020" brass wire. I've used brand-new #11 hobby blades. The best success I have is to press the blade against the rod and then to roll the rod under the blade so that the blade runs around the rod simulating using a parting tool on a lathe. But that's a hit-or-miss proposition and more miss than hit. I'm having difficulty doing two things: 1. Getting a slice that's an even thickness 2. Getting a slice that's thin enough. Using the procedure described above, I have no trouble getting slices about1/16" but even those are often not square.
Obviously a razor saw and miter box are not suitable for something of this scale. What other tools could I be using to fabricate these "washers"?