A huge wheeled heavy plastic box which is to be a case for a battery chargerAbout 18" x 30" floor areaInside reinforcing is a series of small three sided cubicles. About 1/8" thick and 1-1/4" tallBlack polystyrere plasticI need to gnaw down about 30 or so "walls" so gauges, fans and switches fitPower tools include a new Ryobi cordless variable speed drillAnd the mother of all Dremel tools with a 36" umbilical flexible drive shaft. Variable 10 to 30,000 RPMI tried an 1/8" plunge carbide bit but at low speed it skips and jumps and at high speed it is a planet-eaterThe slightest wrist twitch and instant hole through bottom of case Maybe what I need is a cylindrical cutter head 3/8" or even 1/2" in diameter:Flat bottom to minimize cursing and self incriminationsDo any of you Home Handy Hobbiest's have any suggestions? where to find such a tool?As always thank you in advance

Any chance of getting ahold of something like a Stryker saw with the vibrating blade, rather than a rotating one?

If I'm visualizing properly, sounds like a job for a router.

Could you flatten your walls with a circular disk pad bit in the drill, and some very coarse adhesive sanding circular disks? I'm not sure I'm getting the correct mental image of the "cells" inside the larger box, if that's what they are. Sort of grind them flat with a circular disk sanding setup?

I need a picture for my feeble imagination. Just cutting out the reinforcements? I might look at a hot-knife attachment to a soldering iron. Or to cut flush or plunge cut I would use an Oscillating Multi-Tool with a saw blade attachment.

Do you have cut-off wheel attachment for your Dremel? Just like a miniature version of what you would find on a 4 1/2" grinder except only about 1" in diameter and maybe 1/32" thick.

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MEXICOWANDERER

Explorer

Mar 07, 2018

Asking Collective Wisdon Gnawing Plastic Reinforcing Ridges

A huge wheeled heavy plastic box which is to be a case for a battery charger
About 18" x 30" floor area
Inside reinforcing is a series of small three sided cubicles. About 1/8" thick and 1-1/4" tall
Black polystyrere plastic
I need to gnaw down about 30 or so "walls" so gauges, fans and switches fit
Power tools include a new Ryobi cordless variable speed drill
And the mother of all Dremel tools with a 36" umbilical flexible drive shaft. Variable 10 to 30,000 RPM
I tried an 1/8" plunge carbide bit but at low speed it skips and jumps and at high speed it is a planet-eater
The slightest wrist twitch and instant hole through bottom of case
Maybe what I need is a cylindrical cutter head 3/8" or even 1/2" in diameter:Flat bottom to minimize cursing and self incriminations
Do any of you Home Handy Hobbiest's have any suggestions? where to find such a tool?
As always thank you in advance

time2roll
Nomad
Mar 07, 2018
I need a picture for my feeble imagination. Just cutting out the reinforcements? I might look at a hot-knife attachment to a soldering iron. Or to cut flush or plunge cut I would use an Oscillating Multi-Tool with a saw blade attachment.
MDKMDK
Explorer
Mar 07, 2018
Could you flatten your walls with a circular disk pad bit in the drill, and some very coarse adhesive sanding circular disks?
I'm not sure I'm getting the correct mental image of the "cells" inside the larger box, if that's what they are. Sort of grind them flat with a circular disk sanding setup?
Ductape
Explorer
Mar 07, 2018
If I'm visualizing properly, sounds like a job for a router.
fj12ryder
Explorer III
Mar 07, 2018
Any chance of getting ahold of something like a Stryker saw with the vibrating blade, rather than a rotating one?

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Asking Collective Wisdon Gnawing Plastic Reinforcing Ridges

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