13 replies to this topic

[Penna]

I am considering a stampede minimization but most of my shell cuts turn out really rough. I was wondering if there was any techniques or other tools I didn't know about to make shell cuts turn out nice and clean. Thanks in advance.

[CaptainSlug]

Use a better cutting tool. A Band Saw being the ideal, a Jig Saw being somewhere in the middle, and a fine-tooth carpenter's hand saw (one that cuts on the PULL stroke) or box mitre saw being the minimum. Rotary tools are not good when you need to make long straight cuts.

 

If you know your cuts suck, cut wide of your mark then file them to where you need them to be using a rasp and then a file. Plastic is very easy to hand work so long as you keep brushing all the crap off of your file as you go. Touch up the edges as needed with 300 grit sandpaper.

[Silly]

Is a rotary sander bit on your dremel an acceptable alternative to a file, if you use sand paper after?

[CaptainSlug]

No. Buy a rasp and a file. They'll last forever, unlike a sanding bit.

[The2ndBluesBro]

Also, remember to buy a wire brush as well to clean the file effectively. A proper file card/file cleaner is better but a wire brush is cheaper and will get the job done. 

[Bubba Longshot]

I just use a small hacksaw, 180 grit sandpaper, and a small file/ 300 grit sandpaper. These are realatively cheap, and easy to use with some practice. The ultimate cutting tool is a band-saw, so use it if you have access. I'm not sure if this would work, but maybe a scroll-saw? They can cut polycarbonate sheets so possibly plastic? What ever you use to cut though, make sure that you sand the plastic down to give it a good finish. For integrations, use epoxy putty to cover up your cuts if they are really bad... Since you are doing a minimization, however, this isn't really applicable.
Happy modding
Bubba

[Speedr117]

From what I know from other hobbys is that a scrollsaw is just a bandsaw that can do internal cuts. No hands on experience though.
(Sad at thought of heavy nerf equipment and a huge workshop)

[CaliforniaPants]

if you're trying to even out two edges try a technique called "draw filing", where you lay the file across the surface and "draw" it toward you. this gif that I definitely didnt laugh at for five minutes shows doing it in both directions, but I usually just do one to have more fine control over it. files are great and you'll never want to be without them again.

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[Eightdotno]

My cutting always turns out rough also, but I always just clean it up by using a BBQ lighter to melt the uneven space that I cut and then I press the edges on to a flat, cold surface, or on to patty paper, then I wait for it to cool down and then I just use a file and sand paper to clean up what's left.

[Silly]

If its really rough, can you use acetone to smooth it like in 3d printing?

[CaptainSlug]

Acetone vapor polishing is for turning a rough surface into a glossier smoother finish. You won't be able to apply that technique selectively so it would smooth out your entire blaster.

[Silly]

Acetone vapor polishing is for turning a rough surface into a glossier smoother finish. You won't be able to apply that technique selectively so it would smooth out your entire blaster.

Sorry, i just meant the rough edge of the cut, like if your doing, say, a guru, and you want to clean up the crossbow cut you had to do.

[CaptainSlug]

I wouldn't want to put acetone, MEK, naptha, or any other solvents anywhere near a rare blaster shell. Use a file, not a solvent. You're over-thinking something that's really simple to accomplish.

[Vim Fuego]

Good, clean finishes require patience and hard work. There are no shortcuts - unless you can afford a bandsaw, and even then the cut will still need to be filed and sanded smooth... You should never, ever cut right up to your line anyway - remember, you can cut material away easily, it's much harder to add it back on...

 

But above all else; patience.