Here, I've printed out my CAD outlines at
100% size. The clear film is a hunk of Contact adhesive shelf
A step bit and a centerpunch
are handy items to have for this project.
What is, is some tips on hand-making
parts without muss or fuss. And nope, we aren't using the
irst cover the sheet stock
with contac paper. When you go to remove your layouts, you'll
be happy you did. Get some spray adhesive and fix the prints
to your chosen material:
I've covered the black ABS scrap piece
that I'm making my parts from with the contact sheet. Do NOT
try to use clear or Scotch tape- it won't peel back off
easily. It won't, and you'll use TONS of time getting it all
off. Stick with the clear shelf paper, or better yet, and
paper masking tape, the blue stuff is best. I'm cheap, so this
roll here will do just fine.Here, I've cut out my printed layout, and
sprayed the back with good ol' Super90 adhesive.
place center-first, your don't get bubbles under it. Center
let go of the ends. It will drop into place without
Then mark and drill the holes. Do this
with the parts still in as large as possible chunks. This will
minimize fixturing, you can save a bunch of time doing this.
Then cut out your parts using a Scrollsaw:
Rules of thumb:
1. Keep the parts in ONE CHUNK as long as
2. Cut away all outside
3. Then make as many
'detail' cuts as needed while they are still easy to hang
onto. Save final separation of parts until last.
TOP SECRET: Use these, and only these,
Vermont American #30423
5 inches long, 11.5 teeth per inch, .045 blade
depth, .017 thick.
Cuts ABS and PVC
like butter. Slow speeds are best for ABS.