Making rectangular windows in resin- which tools?

scratchbuild · Post by **scratchbuild** » Fri Aug 28, 2009 1:50 pm

Hi and thanks in advance! I'm finishing up this scratchbuilt ship from E.T. The Exra-terrestrial and need some advice.

I need to carve in rectangular windows into the upper hull. Does anyone have any tips/tricks for doing this? The needed rectangles are very small (about 4mm tall and 2mm wide) and will be carved into resin.

Ive already tried drilling a circular hole and then using a square mini file to shape the hole but this is a no-go. It's too erratic. I'm thinking somewhere out there is a metal stencil and a special dremel bit I can use??

Here's a photo to give you a better idea:

http://i876.photobucket.com/albums/ab32 ... ochup2.jpg

why I need the rectangular windows:

http://i876.photobucket.com/albums/ab32 ... /ship2.jpg
http://i876.photobucket.com/albums/ab32 ... erence.jpg

Johnnycrash · Post by **Johnnycrash** » Fri Aug 28, 2009 2:20 pm

Are these window holes open to the inside?? Either way, make a hole larger than needed. Not hugely so, but bigger. Cut a piece of plastic the exact size of the hole needed. Add some release agent to the plastic template, stuff the plastic in the hole, and then fill the gap with filler, and let it squish out all over the place. Let dry. Remove the plastic, sand surface smooth. Should work.

Shinnentai · Post by **Shinnentai** » Sat Aug 29, 2009 10:23 am

I was gonna say wee tiny chisels, or punches made from sharpened square/rectangular brass tubing, but I like Johnnycrash's idea much better.

scratchbuild · Post by **scratchbuild** » Sat Aug 29, 2009 10:36 am

Thanks so far! Hmmm, I"m liking the punch tool idea ALOT. The resin would totally give way to something sharp that could punch the surface. That's much faster and neater. Where would I find something rectangular shaped (or square would be fine), and hollow, and the right size (about 2-3mm wide)

There are 3 windows per verticle panel section, so 36 windows.

The model stands about 20" tall without the base.

http://i876.photobucket.com/albums/ab32 ... nblack.jpg

Shinnentai · Post by **Shinnentai** » Sun Aug 30, 2009 4:18 am

K&S is a common hobby store brand for brass and aluminum stock like that. Usually found in the vicinity of the Plastruct and Evergreen displays. They make rectangular brass tube, but most model oriented places around here only carry the round rod and tube lines.

In this case, it may actually pay to check with R/C oriented hobby stores first. In my experience they tend to have a wider selection of metal stock. There's a dedicated R/C place way south of where I live that has nearly everything in brass, aluminum, and carbon fiber.

Wish I could point out an online HS, but since this is one of things I usually prefer to buy in person, I'm not at all familiar with who might carry it online.

Or if you've got a grinder (bench or moto-tool bit) and a steady hand you can make one to your own specs out of a nail punch.