At the outset, let me warn you that this topic may sound like an overkill to some. However, I assure you that if you try it, you'll be happy with the results. I tried several techniques of cutting high density theromocole smoothly, these include things like a hot knife and also a  Soldering iron with a needle attached to it. Results were Ok but sometimes messy. Perhaps with practice, I would've got better. I just didn't want to invest time in building a hot nichrome wire cutting stand. I know that works beautifully.

However, after I got my Dremel, I decided to try something.

a. Cut out a circular piece of tin from the end of a can. You can use a Dremel rotary wheel as a template. That way you won't have the hassle of marking the centre as the bit centre hole is already there.

b. Cut it out with a pair of scissors and you will notice that it may not have a perfect circumference. Punch out a hole in the centre. Use a hammer and nail to do this.

c. Mount the wheel on the Dremel and keep a wad/roll of 100 grade Black Emerey Paper ready.

d. Switch on the Dremel and sand the disc to perfection. BEWARE - SPARKS WILL FLY!

e. Once you are happy with the circumference, create a knife edge by sanding the top and bottom edges of the wheel while it spins.

f. You now have a seriously sharp blade that will slice through Thermocol neatly.

Try it and see it for yourself. My apologies to those who feel that this was one lame ass post.

Cheers!

VC,
Chanced upon this thread today. This is one bright and innovative idea I have come across in long time. Why dont you submit this to tower? If they publish it you get a additional discount of 15 USD with your next order.
But I am sure an innovative person like you may not need to order things from Tower :-)    

really interesting!!!

nice idea..

hmmmmmmmm great. will try that.

Thanks Guys! You resurrected an old thread. Flyingboxcar, I had never thought about it (Letting Tower know about this idea). To be honest, it seems like a commonplace idea, as I remember having come across a video in Youtube, where a guy does much the same and amputates a plastic Spiderman figure as a demo.

Grate.

Yes literally "Grate"

Thats the nice idea !
and a one more new application for a Dremel multitool.

Please don't flood every thread that mentions Dremels with your store address.  If you are a seller, make one post with your details, people will find it where ever it is.