15-08-2024, 10:19 AM
As you have the original panels, you don't need a straight edge, and you can also do the rounded corners at the same time. Just bolt them together and use a straight cutter with a guide bearing, e.g. https://www.screwfix.com/p/bosch-1-4-sha...-7mm/994fw
That's just an example - for that money you could buy a selection box of router cutters that includes one.
If the panels are aluminium, a router will cut through them with ease, so make sure only the bearing is able to contact the metal.
There is a slight gap between the bearing and the cutter, so you'll need a shim between the two pieces - otherwise you'll end up with a sharp ridge on the plastic, which could be hazardous during cutting and obviously afterwards.
Anything will do within reason. The minimum thickness is just a case of assessing the gap - usually 1 to 2 mm - and adding sufficient margin to make sure the bearing is always in contact with the original metal panel - between 1/3 and 2/3 of the bearing thickness (most often 5mm), so 4 to 5mm would be a good start. The maximum thickness obviously depends on the length of the cutter.
That's just an example - for that money you could buy a selection box of router cutters that includes one.
If the panels are aluminium, a router will cut through them with ease, so make sure only the bearing is able to contact the metal.
There is a slight gap between the bearing and the cutter, so you'll need a shim between the two pieces - otherwise you'll end up with a sharp ridge on the plastic, which could be hazardous during cutting and obviously afterwards.
Anything will do within reason. The minimum thickness is just a case of assessing the gap - usually 1 to 2 mm - and adding sufficient margin to make sure the bearing is always in contact with the original metal panel - between 1/3 and 2/3 of the bearing thickness (most often 5mm), so 4 to 5mm would be a good start. The maximum thickness obviously depends on the length of the cutter.
