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Well here I needed to make circles for my new build and I needed a way to make pretty decent circles with only my hand tools and my dremel. In most cases this would be cause for disaster in my "shop" but I found something very useful hidden in my Dremel tool kit.
What I am using in this demonstration is 3mm PVC foamboard known as Sintra. Great stuff it is, it's much stiffer than balsa and CAs extremely strong, especially when aided with a little baking soda. So here's the story behind my discovery, One evening this past week I was cleaning up my shop and was putting away the Dremel when I came across the Dremel circle cutter. Knowing I was needing to cut circles I thought I would give it a try, see how it worked and how I could put it to use. Turns out it was fairly simple and I came up with a quick technique as to how I could get all of my circles cut perfectly in a matter of minutes. The set of pictures describes the process accuratly enough, within 15-20 min I had all the circles I needed cut and ready for glueing. I am more impressed with the end result.
So here is where I drew on the circle diameter and center lines required for my build.
The Dremel circle cutter tool setup
I drilled a hole OUTSIDE the diameter I wanted to cut so that I could align the blade. This was important as I wanted the blade edge to trace the outside of the compass line, not the center of the blade. I also predrilled a hole in the center so the disc could spin and be cut.
Notice how it's cutting cleanly as I described above.
Finished discs ready for the next step.
So, nice clean circles ready for any use, without a lathe or anything else, just a Dremel which I have been told is the ultimate modelers tool. Just figured I'd share my experience with it.
Dan
What I am using in this demonstration is 3mm PVC foamboard known as Sintra. Great stuff it is, it's much stiffer than balsa and CAs extremely strong, especially when aided with a little baking soda. So here's the story behind my discovery, One evening this past week I was cleaning up my shop and was putting away the Dremel when I came across the Dremel circle cutter. Knowing I was needing to cut circles I thought I would give it a try, see how it worked and how I could put it to use. Turns out it was fairly simple and I came up with a quick technique as to how I could get all of my circles cut perfectly in a matter of minutes. The set of pictures describes the process accuratly enough, within 15-20 min I had all the circles I needed cut and ready for glueing. I am more impressed with the end result.
So here is where I drew on the circle diameter and center lines required for my build.
The Dremel circle cutter tool setup
I drilled a hole OUTSIDE the diameter I wanted to cut so that I could align the blade. This was important as I wanted the blade edge to trace the outside of the compass line, not the center of the blade. I also predrilled a hole in the center so the disc could spin and be cut.
Notice how it's cutting cleanly as I described above.
Finished discs ready for the next step.
So, nice clean circles ready for any use, without a lathe or anything else, just a Dremel which I have been told is the ultimate modelers tool. Just figured I'd share my experience with it.
Dan
I will have to check my Dremel catalog. You are right about the Sintra, it is great stuff to work with. I was given some by our Fearless Leader (Mr Smalley) to try. Thanks again Tim! 
BD.
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