How to improve edges and corners after cutting with a dremel

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neodark088

Limp Gawd
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Sep 18, 2004
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I need some advice on how i can improve the edges and corners that is produced by cutting with a dremel, my main concern is how i can make the 45deg edges ultra smooth like it was cut out of the factory.. I do not have access to highend cutting tools like laser/waterjet. So doing it manually is my best bet.

And how/what to use to paint the edges black?

 
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I have a set of small files, flat, round, triangle that are great for cleaning up the edges and removing burrs and rolled edges. Little bigger than a jewlers set but much smaller than full size, I guess about 4-5 inches long. Touch up with emery cloth (sandpaper for metal) to give a very smooth "no cuts" edge.

http://shopping.msn.com/specs/3m-co...-x-11-emory-cloth-assorted-grits-pro-pak-9064

Hmm moving this to case mods. Someone else might have a better way.
 
I'll keep the emery cloth in mind, how about sanding it with a 200grit that is attached on a pop sickle stick, would that work also ?
 
A popsicle stick will flex... (if you're going for a razor straight edge) ... For square edges I would use either a file or a solid sanding block (or at least a straight piece of metal stock with sandpaper). You can go to a gun shop or craft store to get a black" paint marker that can be used to paint the edges of metalstock.
 
You might also want to get a deburring tool to get rid of the sharp edge as well. You can get a special one from a number of sources or you might find one on a pipe cutter.

Bob
 
I use the sanding drum Dremel attachment mostly. Can't reach sharp corners but otherwise does nicely.
 
For painting, run a line of masking tape right up to the very edge on the front side of the piece. Cover the entire piece, except for the silver perpendicular edge.

Spray at the edge, and while the paint is still wet, remove the masking tape. If it dries before the tape is removed, your paint will flake.

Rustoleum protective enamel in black. It'll be durable as hell in 24 hours.
 
One trick I learned a long time ago, was to lay down a strip of masking tape over your cut line. The tape will give you a smoother cut edge, and as an added bonus, you can see your pencil line better on the tape.
 
the best thing to do is to drill the corner with a small bit to get a nice smooth radius. this way you dont leave any stress points. then just make your cut so it ends tangent to the edge of the drill hole. then finish it with some nice files and finally scotch brite.
 
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