I am working on my Santa Fe and Disneyland Retlaw 1 Consist using Bachmann coaches. One of the details of the original coaches is a window on both sides of the door at both ends. Being fairly new at this I would like a suggestion or two on a tool or tools to cut a window cleanly. I have a Dremel tool but am afraid it might cause more damage by melting the plastic if it gets too hot. I have Exacto knives and a saw. What do any of you suggest??
Thanks,
Richard
Richard,
I have cut many windows in coaches while converting Accucraft J&S to various EBT style coaches, and I haven’t found a good method!
I usually start by drilling out the 4 corners, which is fairly easy. In theory you can use a coping saw or similar band saw to cut between the corner holes. Most fast saws, like a Dremel disk, will melt the plastic.
There is a general purpose rotary cutter available for your Dremel, the 561 Multipurpose Cutting bit. If you drill out the 4 corners, you can use this tool to cut between the holes. HOWEVER it wanders and wanders all over the shop unless you have the drill firmly supported and the coach clamped down. I found it difficult to clamp the coach body (or the end, in the Accu case) and to provide a straight guide surface for the cutter. The cutter tends to pull the work (coach) through and wander past the end.
A router table is probably the proper tool - a flat bench with the router mounted underneath and adjustable up through the top. They are designed so you can put a straight edge to guide the work, like a table saw. Rather a big, specialized device just for your windows!
Maybe you could mount the Dremel with the cutting bit pointing upwards, then figure out a jog to stop the bit from cutting anywhere except inside your window frame.
The other technique is to re-frame the window after you have rough-cut the opening, like this EBT #3.
If I can somehow clamp a straight edge to my work, I do that. Then I run an Xacto knife along the straightedge, but I run the Xacto’s blade blunt edge of the tip first. I use the blade backward. This removes the plastic from the cut instead of just cutting the plastic. I find that a Dremel melts the plastic, and my Zona saw tends to leave a bit of a ragged hole. But using the Xacto the way I do, I can end up with a very clean hole, it just takes time.
Thanks Pete and David…both great suggestions. Thanks for the picture Pete…that is exactly what I’m talking about.
Richard