How to cut a trench/rebate in Knauf board?

 
  Gremlin Chief Train Controller

I need to cut a trench or rebate into Knauf board, about 3mm deep, 60mm wide and 1000mm long...I expect a Dremel will do it, but what sort of attachment should I use??

Sponsored advertisement

  allan Chief Commissioner

What is Knauf board?
  YM-Mundrabilla Minister for Railways

Location: Mundrabilla but I'd rather be in Narvik
What is Knauf board?
allan
It would appear to be plasterboard of some sort.
  Gremlin Chief Train Controller

What is Knauf board?
It would appear to be plasterboard of some sort.
YM-Mundrabilla
It is extruded foam - XPS.
  lkernan Chief Train Controller

Location: Melbourne
It's the foamboard sheets available from Bunnings.  

I did some work on my layout today which uses the same board using nothing more than an old steak knife and a scalpel blade.
  Gremlin Chief Train Controller

It's the foamboard sheets available from Bunnings.  

I did some work on my layout today which uses the same board using nothing more than an old steak knife and a scalpel blade.
lkernan
But how can I get a neat trench cut, sharp sides and flat base?  I was thinking of some type of routing or sanding device?
  Booly Locomotive Driver

I use a 3/16 router bit
  Booly Locomotive Driver

Should have added that i also have the plunge router attachment , this attachment is 140mm across (so 70mm from the center to the edge). Dremel part no. 335-01 . Hope this helps.
  Gremlin Chief Train Controller

Should have added that i also have the plunge router attachment , this attachment is 140mm across (so 70mm from the center to the edge). Dremel part no. 335-01 . Hope this helps.
Booly
Thanks...mask and goggles, I suppose it creates a lot of dust?
  Booly Locomotive Driver

Yep s##* loads , i do mine outside on the back lawn with the vac cleaner ready !
  DJPeters Train Controller

You could make what is called a hot knife with some resistance wire of suitable rating bend it into shape you need to make the rebate and make a holder that will allow you to move it along as it cuts its way through and gives you the depth you need in the foam. It would give yo a nice cut, hardly any mess and would be quick to do it. There are videos on You Tube about such things if you want to go that route. It would be wise though to use it outside and wear safety equipment while doing it, like breathing masks and shields or glasses etc.
  Gremlin Chief Train Controller

You could make what is called a hot knife with some resistance wire of suitable rating bend it into shape you need to make the rebate and make a holder that will allow you to move it along as it cuts its way through and gives you the depth you need in the foam. It would give yo a nice cut, hardly any mess and would be quick to do it. There are videos on You Tube about such things if you want to go that route. It would be wise though to use it outside and wear safety equipment while doing it, like breathing masks and shields or glasses etc.
DJPeters
Thanks for that...I am somewhere between routing it with a vacuum cleaner attached, and making a hot-wire cutter...and hand rasping it...

Thanks for all the suggestions Smile
  Dazz Deputy Commissioner

thinking way way way outside the box here, but guaranteed almost no mess.

Cut out your 60mm wide and 1000mm long section from the board completely using a sharp knife or blade, push entire section down 3 mm and a glue back into place.

If you do not want the 3mm projection underneath,  push the piece you have cut out and simply cut a section off the bottom then glue your section back in 3mm from the top surface.
  bjviper Chief Commissioner

Location: Brisvegas
I have recently done the same thing to the knauf board on my layout so as to create a slot for the backscene material to sit down into.  I started by using a standard wood router with a 4mm bit, but have since changed to using a laminate trimmer as it is easier to use because of it's size.  Yes it does make a mess, but that is easily cleaned up with a vacuum cleaner, or if you're lucky have a 2nd person follow the router with the vacuum as you go.

A Dremel with router attachment would work well, and all you need is a 3mm router bit which I'm sure Dremel make (or 1/8" even).
  stagehand Beginner

Hi guys, can anyone recommend where to buy the Knauf boards in Sydney, as it appears Bunnings no longer stocks them? Ideally somewhere that delivers for a reasonable price!

Many thanks
  patsstuffnow Junior Train Controller

Google is your friend.

http://www.knaufplasterboard.com.au/store_locator


all you needed to do is google

knauf board Sydney
  stagehand Beginner

Hi patsstuffnow, thanks for trying to help but you've posted a link to an unrelated (and not useful) product.

I've capable of doing online research and have explored several options, and only found companies that sell large quantities (and charge ~$100 for delivery regardless of quantity), rather than the one or two boards I require. I'm unable to pickup myself from the locations on the fringes of Sydney due to work commitments.

Hence my request for recommendations from members here who may have purchased it recently, since Bunnings was the simple option but no longer stocks the product.
  dthead Site Admin

Location: Melbourne, Australia
Hi patsstuffnow, thanks for trying to help but you've posted a link to an unrelated (and not useful) product.

I've capable of doing online research and have explored several options, and only found companies that sell large quantities (and charge ~$100 for delivery regardless of quantity), rather than the one or two boards I require. I'm unable to pickup myself from the locations on the fringes of Sydney due to work commitments.

Hence my request for recommendations from members here who may have purchased it recently, since Bunnings was the simple option but no longer stocks the product.
stagehand


The Extruded foam board from  Bunnings seems to be  sporadically avaliable from some of their stores and not at others. Eltham Victoria has had it a lot.

Still one can look up Extruded Foam Board to see if you can find similar products.

Regards,
David Head
  Booly Locomotive Driver

Just ask at your local bunnings they will check other stores and if available will get it in for you . I managed to grab the last 2 sheets from bunnings kirrawee just before christmas , and when i asked if it was going to be restocked they told me no , but can be ordered in on request .
Hope this helps
Booly
  patsstuffnow Junior Train Controller

Dear Stagehand,
The link I sent was to a KNAUf website. , and among many products they sell is the XPS board in several sizes.  A quick phone call to the phone number in the top right hand corner of the website opens up several options.
One was Bunnings as somebody else mentioned.
They can order products off range or check to see if a store my have stocks of the larger sheet 1200 x 2200 which has been removed from the regular Bunnings range.
The helpful person on the line also advised me of a company who stock the larger sheets and does not charge 100 bucks a delivery.

As nobody else has offered any on the ground experience in Sydney it may explain why Bunnings is no longer stocking the larger sheets.
( possibly lack of demand).

Another approach may be to check out if any friends, colleagues, nearby modellers would be interested in buying a large pack and splitting it to minimise the delivery charge.  A collaborative approach may even unearth a way to obtain/ share/ hire a cutting tool etc and maybe allow a share of information, experiences and even an extra pair of hands to help you assemble your module(s).

Cheers and happy modelling.

Sponsored advertisement

Display from: