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Methods for performing major surgery

1839 Views 12 Replies 7 Participants Last post by  Ozzie21
I need to perform some major surgery on the internals of a Hornby tender so I can fit a large speaker. It's a long time since I have done something like this but my memories are of long and awkward struggles to get a scalpel into just the right place and slowly hacking parts away at great risk to the model and my fingers. There's got to be a better way, so I was wondering what methods people use. I am considering a Dremel fitted with a cutting disc, perhaps running from a flexible shaft.

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Other than when cutting through external parts (when a razor saw or sharp knife is the tool of choice) I rarely use anything but the dremel, and often with the flexible drive. The cutter of choice is a milling head about 10mm diameter with fairly coarse teeth, about 2.5mm pitch. At high speed this chips the plastic out, rather then tending to melt it, a particular problem with abrasive discs: one moment cutting, and the next producing volumes of plastic 'candy floss'. Some polymers cut best if left to chill for 30 minutes in the freezer, between attacks.
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