Cutting pre-made cases without melting (using a dremel)

[limpport]

Whenever I try to cut any sample case (like from OKW or Polycase) with my dremel, it ends up melting the plastic. It there a type of cutting wheel for dremels that won't heat it up enough to do melt? It difficult to cut straight lines when it does that, and eats through my cutting disks.

[thewise1]

Have you ever tried a diamond wheel cutter. It may cut fast enough to not melt. And they last a long time.

[hailrazer]

That's why you cut a bit back from the line and then file it down to where it needs to be.

[Rekarp]

That's why you cut a bit back from the line and then file it down to where it needs to be.

Aye

[snowpenguin]

That's why you cut a bit back from the line and then file it down to where it needs to be.

Have a cookie.

[collinE]

Try lowering the speed so that it cuts slower, but doesn't heat it up as fast with higher friction. I had the same problem and didn't want to take the extra time to file it down.

[limpport]

My dremel has 2 speeds, and the slower one does the best job. I'll need to get some files. Does any old file work, or do you guys use something special. I'm guessing you sand the edges after filing.

EDIT: Just found this in another thread (thanks hailrazer):

Sandpaper. You will want :

80 grit
180 grit
320 grit
600 grit
2000 grit (If you want glassy smooth)

Files , just get a multipurpose file set. The kind with round/flat/triangle/etc files of different sizes.