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Old 07-03-2010, 03:17 PM
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Cutting a circle with dremel tool.

Well jumped into the overheating project on my amplifier this weekend thinking it would be a quick job. Now I'm stuck sitting here with a amplifier in pieces, and top cut but not in the circle I wanted it cut (didn't go outside my lines thankfully).

Anyone have any advice on cutting a circle (4 inch) with a dremel tool? Its a aluminum case, so my plasma cutter is out of quesiton now .

Thanks for the advice,
Eric

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Old 07-03-2010, 03:23 PM
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It helps if you can find something close to the size you need to use as a guide, I have had good results doing it that way.
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Old 07-03-2010, 03:30 PM
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What attachment did you use? Thats my main problem, the cutting disks are to fragile, while the reenforced disks are to large for the cut and wear out to quickly.
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Old 07-03-2010, 03:38 PM
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Sounds like you now need a carbide burr for aluminum , or several sanding drums or cartridge rolls, to clean the rough hole out to the line.

Your plasma cutter WILL cut aluminum too, I have done it a lot of times, works just like it does on steel.
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Old 07-03-2010, 03:40 PM
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ericnova72,

I'll give the plasma cutter a shot if you think it'll work, the metal is maybe 1/8th inch is some places, but has some bracing. I've never tried with aluminum, any advice?

Thanks, Eric
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Old 07-03-2010, 04:15 PM
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It cuts just like steel,... just has prettier sparks . The plasma cutter will cut most anything metallic...steel, aluminum, copper, brass, titanium, cast iron, etc
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Old 07-04-2010, 01:42 PM
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My guess is you don't want to go out and buy a new tool, but a Roto-Zip (this metal cutters and a circle cutting attachment) should do the trick. I can't remember what I paid for mine but I think they are under $50 at the big box stores. I think they also make a circle cutting attachment for your
Dremel but I don't think the motor is up to the challenge.
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Old 07-04-2010, 04:45 PM
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[QUOTE=ericnova72]Sounds like you now need a carbide burr for aluminum , or several sanding drums or cartridge rolls, to clean the rough hole out to the line.

Those were My thoughts also, use a burr to rough in the hole, then smooth it with the sanding drum.
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Old 07-04-2010, 11:17 PM
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Thanks for the help everyone, I used the plasma then used the sanding drums to finish it up and it worked perfectly.

The amplifier hasn't gone into thermal protection again. Really pushed it pas any comfort zone for me and the fan pulling air through thr case works wonders .
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