Band saw with a thin blade (.025" and about 10 teeth per inch). In order to fill the slot I had to use some fairly heavy brass, 0.016", which makes for more difficult bending.
For the thinner stuff (0.010"), I can use my dovetail saw, which leaves a .022" kerf. A hand saw needs to filed to a rip cut, as you will be cutting into the end grain.
If you use the Dremel, you might want to put it in a vise or something to make it immobile, and move the piece into it, rather than the other way around. I think that would give you more control over it, and keep the kerf as narrow as possible.
Another thing you might try is the plunge cutting attachment for something like this. Multifunction Oscillating Power Tool - 1.6 Amp, 120 Volt I have the Fein version, which comes with a small plunge cut blade 0.02" thick. Now that the Fein patent has run out, everyone is making cheaper knoockoffs. Here is a video showing the plunge cut function. FEIN MultiMaster 250Q The Plunge Cut3 Hardwood Flooring - YouTube At about 3:30 into the video, they change to the thin blade, which is the one I have and would be the one you would want for pens. MM133, Universal Arbor 2-5/8" Plunge, Fine Wood Saw Blade, 1 pc (this should work, though it doesn't list the thickness, you would have to make sure it's thin enough). This tool should also be able to make the cut for the traditional mounting method.
I think the HF model would serve you well for such light use.
Edited by DanF, 16 May 2013 - 08:27.