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Author Topic: cutting carbon sheet  (Read 1813 times)

Offline BillLee

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cutting carbon sheet
« on: June 25, 2014, 08:12:14 AM »
I need to cut some carbon sheet. In the past I have used my bandsaw but found that one cut pretty much destroys the blade.

I need to shape the plate to the outline of a profile fuselage, so we're talking about cutting many inches. Plate is something like .045" thick, or perhaps a bit thicker.

Any tips for how to cut this stuff?
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Offline bob whitney

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Re: cutting carbon sheet
« Reply #1 on: June 25, 2014, 08:15:34 AM »
Bill not sure when u posted this  but an air grinder with a cut off wheel  works good ,thats what i use to trim my props
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Offline Tim Wescott

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Re: cutting carbon sheet
« Reply #2 on: June 25, 2014, 08:29:29 AM »
I used a coping saw, and tossed the blade when I was done.  You may need to use a few blades to cut that out.

It may be less complicated to get some cloth and vacuum-bag it onto the fuselage, instead of trying to get already-made stuff.
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Offline Steve Helmick

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Re: cutting carbon sheet
« Reply #3 on: June 26, 2014, 09:39:38 PM »
I was out flying with Mike and he had his new carbon handle. The subject of cutting the outline came up, of course, and he said he drilled a lot of holes to reduce the amount of sawing required. I'm thinking I'll do that, and use my Dremel jigsaw to connect the holes. Cheap blades, and they don't last long anyway. I haven't figured out what drill size would be best, but somewhere between 1/8" and 1/4" should do. I may have some carbide drills left from my contract machining days, but I don't think those are ideal for CF. I believe they have a special drill for CF at your machine shop supply stores...but not Ace or Lowe's.  D>K Steve
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Offline Mike Haverly

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Re: cutting carbon sheet
« Reply #4 on: June 26, 2014, 09:58:57 PM »
     I use regular ~1/8  HSS drills.  They will get dull but you can get many holes before any serious damage.  No need for carbide, CF is so abrasive the carbide is not cost effective in this application.  I sharpen my drills as long as the margin isn't too bad.  Leave about 1/4" between holes and connect the dots with a Dremel abrasive disc.  After that it's a simple matter of a belt sander or drum sander or file or.... Of course, a dust mask is mandatory. 

     I also use my scroll saw.  As soon as the blade starts getting dull, put a piece of 1/4 balsa under the work piece exposing a fresh set of saw teeth.  It will get dull again.  Do the same thing with 1/2 balsa or another piece of 1/4.  Kind of like shark teeth in many rows.  You can cut quite a while like this, then of course, the blade is toast.
Mike

Offline david beazley

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Re: cutting carbon sheet
« Reply #5 on: June 27, 2014, 05:02:55 AM »
I have a Dremel scroll saw that uses holders with set screws to hold the blades.  I have taken a carbide grit rod saw blade for a hack saw and cut it to fit the holders.  It works well in carbon sheet and fiber glass sheet.  Also there are several blade manufacturers who make carbide grit edge jig saw blades for hand held jigsaws.  Avoid carbide tooth blades as they tend to split the material being sawn.  The grit edge "sands" the material away as you cut.  Hope this helps.
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Offline Howard Rush

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Re: cutting carbon sheet
« Reply #6 on: June 29, 2014, 12:56:07 AM »
I use diamond blades for my table saw for straight cuts.  Abrasive wheels work almost as well:10" ones for the table saw for long cuts, the Dremel 420 or 409 wheels for short ones.  Tidy it up with a sanding drum, disk sander, or belt sander. 

However, David's idea sounds good, and I intend to copy it.

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