from the dremel site i use cutoff wheel 426. they are not as good for real hard stuff (like steel sidepanels). but i just found out that they don't wear down from copper.
what they always told me in school, the softer the material, the slower the rpm (so that the surfaces don't heat up as much, less friction) look at it like cutting plexi with dremel at 30.000rpm. the plexi just melts instead of being cut. so try putting your dremel at half speed, that will work wonders. same goes for the drills, did all the holes at 1800, and u can move in on the hole like if it were butter. real fast, and in 1 pass.
if u already did everything at slow rpm, then i just guess its the dremel wheels that are holding you back.
distance from rim to rim is 1mm, didn't think i would be able to get em closer because of fault tolerance. now i c that it was possible to have them at 0.5 no problem. next time i think i will use 4mm drill instead of 3.5, because at 3.5 i don't have the concave sides of the squares, they are almost all perfectly square. so the beloved turbulance effect rotor always speaks about will occur less with the 3.5 mm holes (dremel is 1mm thick, so 3.5 - 1 = 2.5 => 2.5/2 gives u only 1.25 of possible concave side. if u were to use 4mm : 4 - 1 = 3 /2 is 1.5 of concave area.
dunno if it is alot of difference, but worth a try
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