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Hardware and Case Mod's You Paint it, Cut it, Solder it, bend it, light it up, make it glow or anything like that, here is your forum.

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Unread 12-31-2001, 12:48 PM   #1
grep
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Join Date: Mar 2001
Posts: 37
Default How to cut perfect holes using a dremel tool

Problem - when cutting holes for fans using a dremel tool the holes often come out pretty ragged looking.

Solution - use a pattern. A thick piece of plastic with a precut hole sized to the dremel tool. You clamp the plastic pattern to the work piece and then cut out the hole with the dremel tool by just pressing against the pattern and it should make a perfect hole every time.

Method - Dremel tools are standard sized. a manufacturer could make a set of patterns for 60mm, 80mm, 120mm out of 1/4" plexiglass and sell them as a set for a couple of dollars.

Explanation - This is an old wood workers trick to make complex shapes in wood using a router (oversized dremel tool) The pattern takes in to account the size of the router base and duplicates the original shape, the wood worker just presses the tool against the pattern as he cuts the wood and produces a perfect copy every time.

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Unread 12-31-2001, 01:01 PM   #2
grep
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Join Date: Mar 2001
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Default details of hole cutting

I am assuming that the dremel is being used like a free hand vertical milling maching to cut the hole. If you measure from the centerline of the milling tool to the outer edge of the base of the dremel tool you get a measurement, lets say this is 1", so if you want to make a 3" radius hole you make a piece of plexiglass with a 4" hole. now you can make 3" holes all day long and each hole will be perfect.

Anyone with a milling machine can easily make the patterns out of plexiglass. All you need is to go to a store that sells dremel tools and measure the base on every dremel tool that dremel makes and just keep this in a data base. Now you start advertising. When you get an order you ask the model of the dremel tool they use, and pull that info from the data base and in abt. 10 min, you can easily make the pattern.

This would be great for someone who makes water blocks and things like that for the overclocking crowd. When you don't have enough orders to fill to keep going. deversify and make other products like patterns for cutting holes.
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