Helmets How to Cut Plastic without a Dremel Tool

Ken H

Ken H

Joined
Dec 15, 2004
Messages
358
Location
Liberty Hill, TX
Bike
2011 BMW R1200GS
Any Other Ways to Cut Plastic without a Dremel Tool?

I want to cut down a face shield that I use with my full face helmet. Short of buying a Dremel tool or something similar are there other methods of making good clean cuts in plastic like that? I have a Roto Zip but unless I am missing something there is not a way to make a good clean controlled cut with a Roto Zip.
 
Last edited:
A cylinder with sandpaper chucked onto a drill held in a vise.
The same cylinder in a drill press.
A belt sander...
 
I work with a lot of plastic, find the best way is to cut the shape with a bandsaw. Protect the surfaces with blue painters tape. Not too fast of blade speed and a fairly fine tooth blade. File the edges smooth with a medium file - it will look like a factory piece if done right.
 
Dave-
I dont have a bandsaw but would a fine tooth hacksaw blade work? And cover over where the cut will be with painters tape or just up to where the cut will be?
 
Fine hacksaw may work although a fine coping saw may be better for radius cuts.
Rule of thumb You want 2.5 to 3 teeth of engagement to minimize chips.
Lower speed speed means less likely to melt the edge.
Tape will prevent scratches to the surface and help with blowout on the edge.
 
Tape on BOTH sides of the cut. DAMHIK:) But it has to do with cutting wind screens...I have a REALLY short one:)

I have used a 'jig' saw with a very fine blade, too. I DON'T like the dremel/rotary tool, too much melting. Finish with a file then fine sand paper.

I've never cut a face shield, I would imagine that minimizing movement and vibration would be critical to a smooth cut on a piece that thin. Use way too much tape to avoid scratches all over the shield.

Good luck, and let us know how and what you did.
 
If you are very patient and careful, an Xacto/razor knife will also do the job.

Tape up the shield on both sides, so you don't scratch it. Mark where you want your cut, then carefully make a slight cut with the razor. Repeat this several times, going deeper with each pass. Once you are 3/4s or so through you can snap off at the line.

Go back with fine sandpaper or file. You might even want to "flame" the edge (lightly/quickly pass a torch flame across the edge) if you have a plumber's torch. This will make the edge very smooth. TRY 1st ON A PIECE OF THE DISCARDED PLASTIC.
 
Highrider said:
I work with a lot of plastic, find the best way is to cut the shape with a bandsaw. Protect the surfaces with blue painters tape. Not too fast of blade speed and a fairly fine tooth blade. File the edges smooth with a medium file - it will look like a factory piece if done right.
Click to expand...


Well, got the job done. Turns out my dad had a scroll saw in his shop. We used it to do the cut down. It worked great. Variable speed and a fine tooth blade. Finished off the cuts with a sander. The cut down shield came out in great shape.
 
You must log in or register to reply here.
Back
Top Bottom