pavius.net

When I started making prototype boards, I couldn't find a Dremel accessory to help me cut the boards to size. A perfect tool would be some sort of table saw contraption, but there is no such thing. After a few experiments, I found a quick and accurate way to use the Dremel for this purpose.

The first thing I noticed is that it makes much more sense to move the board and not the Dremel tool when cutting. To accomodate this, I use a clamp and the Dremel extension cable with a disc saw bit attached. The reason for the extension cable is that it is smaller in diameter than the disc saw bit (as opposed to the Dremel tool itself which is larger), so it allows you to slide a board over it.

The next thing you do is wrap the extension with some sort of cloth, because you need to clamp it. This gives you enough stability without damaging the extension accessory. Note that you should mount the accessory so that it spins away from you.

You can then safely and easily guide your board into the disc saw - leave about 1-3mm of slack. After you perform the cuts, use a file to remove the slack and straighten the cut. You can also use the file to round the edge of the cuts.

Clamp the board and use a diamond bit (or similar) to make cuts in the veroboard, if necessary.

Make the cuts by holding the dremel vertically, as stable as you can, and guide it through.

Notice that I had to make some really fine cuts here (cut between two adjacent holes) - the diamond bit makes easy work of this as long as you keep it at a 90 degree angle to the board.

Mount your components and test. This specific board is a breakout board for 28 pin PICs with an RJ12 connector for RealICE.

That's it. Note that you should do this in a well ventilated area with some sort of dust mask and safety goggles. The disc saw bit can break in to tiny pieces at any given moment. The downside to this method is that there is no support for the board during cutting (besides your hands) - I am in the process of fabricating some sort of table for this.