Best way to hollow out resin pieces

Hey guys!

so I’ve got a few resin pieces from multimediamayhem and want to put electronics in them. They’re truly great work - just THICK and solid.

Being a newb - what’s the best way to hollow out the insides to allow for lights and such?

I also have a fiberglass shell that’s too thick around the cyclotron lenses - need to seriously thin that out on the inside. It’s about a half inch thick.

So!!! what do I do?

Dremel tool? Drill with some special bit? Chisel and a hammer?

Thanks in advance for any and all suggestions!

// jayse

I don’t know much about resin, but I do know you need to be careful, so a hammer and chisel is right out, and I also have had experience with a Dremel recently, and it sucked so much I brought it back. You will be there a long long time if you tried to hollow out a piece by grinding it down with a dremel.

So that leaves drilling. I don’t know how safe it is to drill resin, but MMM told me to drill a small pilot hole before drilling a larger one when I asked about drilling out a smaller piece. With a larger piece, maybe cracking won’t be as much an issue, but I’d still take it REALLY slowly.

The best way to remove resin is to use a Dremel with a gnarly bit like this…

http://www.ares-server.com/Ares/Ares.asp?MerchantID=RET01229&Action=Catalog&Type=Product&ID=81959

They’re pretty pricey but if you need to remove a lot of material, this is what you want to use. I bought one a few years ago and it was well worth it.

You could also use the standard Dremel grinder bits but it will take you twice as long, if not longer.

thanks ghostguy… i’m used to using dremels for models - small stuff and love it. I can imagine for bigger stuff you just need the right tips! :wink:

RoboProp - that’s awesome! That’s kind of what I was looking for. I’ll be checking that out.

All ears for any other tips as well!

thanks guys!

// jayse

Hollowing out resin if pretty difficult. Most people I know who want something that’s resin hollow, make a new mold from the resin part, and then just do a slush cast of it. (A new resin part made by pouring resin in th new mold, and moving it around, so it coats the inside of the mold.)

NOT a job for the inexperienced though.

IMO the best way is with a milling machine, hardly practical for most but it makes it almost painless…

while dremeling…have the vacuum going with a hepa filter…stops all the bad resin from going into your lungs…a mask is the preferred way…I have gotten pretty good with dremeling and holding the hose up close to suck up all the flying dust…Its amazing how little cleanup you have to do later.

Gareee - tempting… one day… one day I will know how to do all that…

Exoray… damn you and your great equipment! I’m coming over!

Hawaiiangb - that’s a great idea - I think i’ll do both the mask and the vacuum.

So in essence you are recasting someone elses part?

Hollowing out resin parts is not hard but you do need some tools, a Dremel works well with the bit suggested, a drill press with a Forstner bit or even an end mill if you’re careful.

Yep, you’d have to do a recast for a simple hollow one. No big deal since it’s not for resale, but is for personal use.

I’m not sure how much detail there is, but maybe a vacuform version of it might work? Only thing is, you’ll look all the sharp detail.

Just be careful when you are removing all that material. I burned up a Dremmel when a bunch of resin ended up getting sucked into the fan, and over time the thing ate itself.

Every time I use my new Dremmel, I stop and use my air compressor to blow it out so that fine particles dont lodge inside and mess it all up.

Great tips! really appreciated!