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Open Roads Forum  >  Tech Issues

 > Asking Collective Wisdon Gnawing Plastic Reinforcing Ridges

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MEXICOWANDERER

las peñas, michoacan, mexico

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Posted: 03/07/18 02:14pm Link  |  Quote  |  Print  |  Notify Moderator

  • A huge wheeled heavy plastic box which is to be a case for a battery charger
  • About 18" x 30" floor area
  • Inside reinforcing is a series of small three sided cubicles. About 1/8" thick and 1-1/4" tall
  • Black polystyrere plastic
  • I need to gnaw down about 30 or so "walls" so gauges, fans and switches fit
  • Power tools include a new Ryobi cordless variable speed drill
  • And the mother of all Dremel tools with a 36" umbilical flexible drive shaft. Variable 10 to 30,000 RPM
  • I tried an 1/8" plunge carbide bit but at low speed it skips and jumps and at high speed it is a planet-eater
  • The slightest wrist twitch and instant hole through bottom of case
  • Maybe what I need is a cylindrical cutter head 3/8" or even 1/2" in diameter:Flat bottom to minimize cursing and self incriminations
  • Do any of you Home Handy Hobbiest's have any suggestions? where to find such a tool?
  • As always thank you in advance


fj12ryder

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Posted: 03/07/18 02:26pm Link  |  Quote  |  Print  |  Notify Moderator

Any chance of getting ahold of something like a Stryker saw with the vibrating blade, rather than a rotating one?


Howard and Peggy

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Posted: 03/07/18 02:35pm Link  |  Quote  |  Print  |  Notify Moderator

If I'm visualizing properly, sounds like a job for a router.


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MDKMDK

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Posted: 03/07/18 02:35pm Link  |  Quote  |  Print  |  Notify Moderator

Could you flatten your walls with a circular disk pad bit in the drill, and some very coarse adhesive sanding circular disks?
I'm not sure I'm getting the correct mental image of the "cells" inside the larger box, if that's what they are. Sort of grind them flat with a circular disk sanding setup?


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time2roll

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Posted: 03/07/18 02:52pm Link  |  Quote  |  Print  |  Notify Moderator

I need a picture for my feeble imagination. Just cutting out the reinforcements? I might look at a hot-knife attachment to a soldering iron. Or to cut flush or plunge cut I would use an Oscillating Multi-Tool with a saw blade attachment.


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STBRetired

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Posted: 03/07/18 03:28pm Link  |  Quote  |  Print  |  Notify Moderator

Do you have cut-off wheel attachment for your Dremel? Just like a miniature version of what you would find on a 4 1/2" grinder except only about 1" in diameter and maybe 1/32" thick.


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DrewE

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Posted: 03/07/18 03:34pm Link  |  Quote  |  Print  |  Notify Moderator

Several options come to mind, if I'm understanding properly, depending on one's specific needs (shapes to be cut and the like). I'm not sure I have a complete view of what you're trying to accomplish, though.

If the goal is not through holes but just removing reinforcement material on the inside without going through the outside skin, a router with the depth adjusted appropriately is about the best option I can think of. The base plate is the key here to controlling things. Just manipulating a router bit completely freehand would be very hard to control (as it sound like you have already discovered). The Dremel router attachment would probably do okay here.

For largish round through holes, a hole saw in a drill would probably be tough to beat. For smaller ones, obviously one uses a plain old drill bit.

For mediumish to reasonably large through holes with straight line sides, an oscillating multi-tool would be good. These are remarkably handy, not the fastest cutters in the world, and can do some cuts that are pretty much impossible to make otherwise.

A jigsaw/saber saw would also likely do the trick for through holes, though may tend to leave somewhat rough edges.





MEXICOWANDERER

las peñas, michoacan, mexico

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Posted: 03/07/18 04:13pm Link  |  Quote  |  Print  |  Notify Moderator

[image]

This will give a general idea. The reinforcing ribs are deeper inside

This is going to be a 135 amp fully adjustable battery charger

[image]

[image]

Different box but this is the only example of what's inside my box.

A frustrating problem for me. Lose the ribs! [emoticon]

mobeewan

Hampton, Va

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Posted: 03/07/18 04:25pm Link  |  Quote  |  Print  |  Notify Moderator

Ryobi-18-Volt-ONE-JobPlus-Base-with-Mult........nt-Tool-Only (oscillating saw tool head)

Uses flat ascillating saw blades that can cut flat against objects. Might be able to set the flat blade against the desired surface to cut the ribs flush with that surface.

STBRetired

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Posted: 03/07/18 05:22pm Link  |  Quote  |  Print  |  Notify Moderator

[image]
[image]
One of these in your Dremel will cut those ribs with minimal issues. Cuts 90 degrees to the axis of the Dremel so makes it simple to get the tool into the box.

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