At the outset, let me warn you that this topic may sound like an overkill to some. However, I assure you that if you try it, you'll be happy with the results. I tried several techniques of cutting high density theromocole smoothly, these include things like a hot knife and also a Soldering iron with a needle attached to it. Results were Ok but sometimes messy. Perhaps with practice, I would've got better. I just didn't want to invest time in building a hot nichrome wire cutting stand. I know that works beautifully.
However, after I got my Dremel, I decided to try something.
a. Cut out a circular piece of tin from the end of a can. You can use a Dremel rotary wheel as a template. That way you won't have the hassle of marking the centre as the bit centre hole is already there.
b. Cut it out with a pair of scissors and you will notice that it may not have a perfect circumference. Punch out a hole in the centre. Use a hammer and nail to do this.
c. Mount the wheel on the Dremel and keep a wad/roll of 100 grade Black Emerey Paper ready.
d. Switch on the Dremel and sand the disc to perfection. BEWARE - SPARKS WILL FLY!
e. Once you are happy with the circumference, create a knife edge by sanding the top and bottom edges of the wheel while it spins.
f. You now have a
seriously sharp blade that will slice through Thermocol neatly.
Try it and see it for yourself. My apologies to those who feel that this was one lame ass post.
Cheers!
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