Cutting Lexan Bodies

[Ericke1]

I have been using my Duratrash (mean Duratrax) Lexan Scissors to trim my bodies and a reamer to make body posts holes. Very dissatisfied with the quality of the but when using the scissors.

I have heard people use Dremels to trim the bodies, at least for the perfect engine cutout or fuel access cutout. Can someone help me with what to use other than a protractor? I'm assuming there is a dremel perfect accessory I will need to make those percise body cutouts.

Please enlighten me

 

[joneser4u]

I use scissors and a reamer? For holes in the windshield I use a shotglass to draw my circle use the reamer to start a hole then use the scissors to cut. I've had good sucess with these tools. Maybe its time for a new pair of scissors?

 

[Rolex]

I'd be absolutely helpless without 3 pairs of Lexan shears and my dremels. 2 Dremels, each with a different sized collet. 3 shears, each with a different cutting angle. Sharp turn, shallow turn and straight.
Other than that, THIS is all you'll need......

These are my primary tools. The tapered stone is for cutting the body mount holes after drilling a small starter hole. Work all 4 holes at the same time, and as you enlarge them, keep checking the fit till they are all perfectly centered and an exact fit to the posts. The sanders are for cleaning up the curves and body lines after cutting with the shears.

 

[Ericke1]

Do you know what part numbers those are for the Dremel?

 

[Rolex]

Sorry, I have no idea. What's in that kit is a compilation of many parts from several places. Hobby shops, Home Depot and Lowes are the 3 best places. Particularly Home Depot. They have a great assortment.

 

[robmob]

95% of the cuts I make on bodies are done using the score and snap technique. The only real exception is the window cutout which I use an Olfa circle cutter. Even with that I only score the circle then use scissors to create some cuts up to the score line inside the circle. I then snap the pie shaped pieces out.

For straight lines, I will put a piece of tape on the body to use as a straight edge. I then score along the edge of the tape.

IMO, this is the easiest and cleanest method. It does require a steady hand.

Thread moved to the body shop since thread starter asked a general question and did not post a review or how-to.

 

[Ericke1]

Rolex, the stone bits for the dremel dont look sharp, do they actually cut or just apply pressure to bore the hole larger?

 

[fearthis7208]

I have purchased two different dremel kits and both have come with some acc. so that may be the thing to try, I personally dont have a clue for cutting these things though....I know wal-mart use to have some pretty nice kits not sure if they still do or not.

 

[Rolex]

Rolex, the stone bits for the dremel dont look sharp, do they actually cut or just apply pressure to bore the hole larger?

It grinds slowly. It takes patience since it will melt the lexan if you rush it, and that's the advantage of working all the holes together. It gives time for the previous one to cool down. When checking the alignment to the posts, just make note of which way you need to add pressure to center it. Since it's tapered, you get it exactly the right size. When they are done, I just run an e-xacto around the edge to remove the rim it leaves.

I get an immaculately perfect set of mounting holes every time.

 

[Lessen]

95% of the cuts I make on bodies are done using the score and snap technique. The only real exception is the window cutout which I use an Olfa circle cutter. Even with that I only score the circle then use scissors to create some cuts up to the score line inside the circle. I then snap the pie shaped pieces out.

For straight lines, I will put a piece of tape on the body to use as a straight edge. I then score along the edge of the tape.

This is the EXACT same method I use... with the exception of the circle cutter because I don't have one. When I cut out a body I run automotive pinstripe tape around the entire perimeter, including wheel wells. I find this method to be the absolute cleanest way to cut out a body... bar none. The philosophy is the same as painting... 95% of the work is in prep. If your prep work is good your final result will be great.