It's composite time...

[Kyle Boatright]

Originally Posted by DRMA

I haven't tried the oscillating tools, but found the large 3" disks that Van's provides were too crude, hard to control, and caused a lot of dust. What worked best for me was a Dremel tool with the small 1" diamond blades from HF. http://www.harborfreight.com/diamond...-pc-69657.html These cause a very fine cut so not a lot of dust and are easy to control. Just plan on changing the disk reasonably frequently. I think I've gone through about 5 of the packages of 5. Other builders have also said they had the best results with the Dremel tool.

Sadly, I've killed one dremel on this project already. Apparently a tool which creates dust by design is subject to failure due to dust ingestion. .

[salto]

You can get dremel cutting discs now that click on click of. Have a much stronger centre than just the screw. 👍

[DanH]

A good jigsaw does cutoff work with a lot less dust.

BTW gents, the kind comments are appreciated, but I'm just a homebuilder, like you. There are lots of good composite guys here. I'm just a TC who takes the time to explain things on VAF. Truth is, most of the real pros don't have the time. They're in the shop, making a living.

[60av8tor]

Originally Posted by Kyle Boatright

Sadly, I've killed one dremel on this project already. Apparently a tool which creates dust by design is subject to failure due to dust ingestion. .

Same here, Kyle. I quickly learned that my dremel was not up to the task of the cabin top. It killed me, too, as I get attached to dumb things - had that dremel for probably 12-13 years

[DRMA]

My Dremel 4000 has held up well to extensive use on my RV-10, including full trimming of the cabin top and Plexiglas. I do "clean" it out occasionally using an air nozzle on my compressor hose to blow out all of the vent openings.

[Bill Boyd]

... pretty good progress - rough trimmed everything except window openings to the plans dimensions/scribe lines. Used a combination of the HF oscillating carbide blade in my Porter Cable 20V multi-tool and a Bosch grit blade in my jigsaw. Easiest technique was to start the cut lines with the oscillating tool which is a little easier to steer precisely, and finish by running the jigsaw through the shallow kerf - the jigsaw blade lost its initial sharpness early on, and seemed to 'appreciate' the pre-cut groove to follow through the thicker flanges. I didn't bother with either a face dust mask or holding a vacuum hose near the tool, as the dust from both tools settles quickly to the floor. Very different from the cutoff wheel.

I found that the factory cut lines yield a doorway section that is 37-1/2"wide, to fit inside a fuselage rough opening of 37-1/8" width. Clearly there will not be much material left in the vertical sides of the fiberglass doorway area by the time I am finished narrowing them to 37-1/8" OD with a belt sander. Pictures of other builds seem to indicate this is pretty standard.

[bret]

Originally Posted by DanH

A good jigsaw does cutoff work with a lot less dust.

BTW gents, the kind comments are appreciated, but I'm just a homebuilder, like you. There are lots of good composite guys here. I'm just a TC who takes the time to explain things on VAF. Truth is, most of the real pros don't have the time. They're in the shop, making a living.

Well, I am just one of many I'm sure, who thank you for taking the time to explain, I have learned a lot from your comments on here regarding FG and many other subjects. Thanks!

[DRMA]

Originally Posted by Bill Boyd

...

I found that the factory cut lines yield a doorway section that is 37-1/2"wide, to fit inside a fuselage rough opening of 37-1/8" width. Clearly there will not be much material left in the vertical sides of the fiberglass doorway area by the time I am finished . . .

I found the same thing - had to remove so much material to get the cabin top to fit that I became concerned and called Van's Builder Support. They confirmed that there will not be much material left, and that the scribe lines are wide of what you eventually need.

[Bill Boyd]

As promised, a bit of followup on my experience thus far with abrasives and the cabin top. The carbide cutter in the oscillating tool is the most controllable and works well in the thinner parts such as the window cutout flanges. It also makes a nice pilot groove to follow with the jigsaw carbide grit blade. But the tool that comes closest to "like butter" cutting action on the thicker parts is this one -

http://www.harborfreight.com/media/c...image_8090.jpg

Note that it is more of a shaping tool than a cutting tool (unless you want an inch wide kerf), and it throws dust everywhere unlike the other blades I mention above that merely dribble fine powder at your feet. I ended up using all three to good effect.

[Gary 40274]

Originally Posted by Kyle Boatright

Sadly, I've killed one dremel on this project already. Apparently a tool which creates dust by design is subject to failure due to dust ingestion. .

One little known fact is that if you return the Dremel they will replace it at no charge

Gary Specketer