Cutting Aluminum Passenger Car

For quality cut I would use a band saw.  I agree with you to much of a risk that the dremel will get away from you.

I did use a Dremel cutwheel. But first I masked the cut line with heavy duty duct tape and then cut one flute line below that so if it did get away from me, no harm. A file took it to the masked line.

Terry

@Will Ebbert posted:

I have a Golden Gate Depot aluminum passenger car I want to remove the skirting from. My first thought is to use a Dremel, I'm just afraid it will get away from me and cut somewhere I don't want it to. Any suggestions or alternatives? 

A chop saw with a fibreglass cuttung disk is what you seek.

Clamp a wood or metal straightedge to the car.  Be sure you clamp it to the good part (covering it) that you want to keep.  Then you could safely slide your cut-off disk along the straightedge to take off the skirting, without accidentally marring, nicking, or gouging the body. 

First off take the shell off the car. Then cut on the inside. Put some magic marker down in area area you want to cut, then scribe a line with a pointed steel tool. Cut just outside the line and finish with a file or sandpaper mounted to a block.

ESE Pullmans had skirts. Have you considered hacking up something else like a Lionel plastic car for this project?

Pete

If feasible, try your process on some similar, scrap material.

You can try a Dremel with the metal cutting wheel, but put the routing attachment on to control your depth. 

Use a cutting disk in your Dremel, take your time, and control your Dremel.

A bandsaw will cut it but it’ll cut both sides at the same time unless you angle the shell so the bottom or top side stays out of the way. Chances of cutting both sides at the same time and keeping the cut from wandering is slim.

Cut near the line you want but not the exact line, this will help prevent those unwanted cuts and use a file to clean up.

Remember, the hardest part of any modification is making that first cut.  Secure the shell so it doesn’t move and use both hands to control the cut.

 I removed every other flute on an aluminum OK Engines shell to make my first Seaboard Air Line Sun-Lounge car, using my Dremel, files, sandpaper, and polishing compound to do the job. It’s not impossible, just be patient use plenty of lighting.

Any particular reason? What will you use for under body details?

Best wishes but I would never do that to my skirted cars.  Especially a nice SS model.  Too easy for the job to turn out knurlie.

If you know anybody with access to a manual machining mill, that would be the best way. You can make sure the shell is clamped secure and buzz off the skirting with an endmill. It will leave a nice clean straight edge, wouldn't take long and extremely low risk of damaging the car. The other options of using a bandsaw or dremel are pretty risky, unless you are well practiced in using them.

I found the only way to cut extrusions is with an end mill, a special clamp, and lots of green cutting fluid.  I bet I have cut over ten blanks that way, including skirts.

But if you have a steady hand the Dremel with the thin cutoff discs and a file will work.  You will want a brand new file.

The discs will load up quickly, so plan to eat up five or six.

I am kind of with Tom - shame to cut up such a good looking model.

Thanks for the suggestions guys! 

I'm cutting the skirt because I'm modeling a present day private car that had it removed (NYC 43). This is the most accurate model I've found and I got it for a great price.

This car?

http://www.rrpicturearchives.n...ture.aspx?id=1161759

You are really going to be cutting a lot of fluting off! Looking forward to seeing your progress.

@BobbyD posted:

This car?

http://www.rrpicturearchives.n...ture.aspx?id=1161759

You are really going to be cutting a lot of fluting off! Looking forward to seeing your progress.

That thing looks very ugly without the skirting!

That's the car but it's had a lot of work done since that photo and some of the skirting added back. I saw it in 2016. Hopefully it got done more avid baths to clean the roof but it's a decent looking car. 

  One could also try cutting the skirting off with a razor saw and some cutting fluid.

  Lots of elbow grease required and time, of course.

  I will be cutting skirts off some of my plastic Lionel 21” coaches in accordance with CPR prototype and will using a razor saw(less chance of damage I hope)

Al

@albertstrains posted:

  I will be cutting skirts off some of my plastic Lionel 21” coaches in accordance with CPR prototype and will using a razor saw(less chance of damage I hope)

Al

I have cut the skirting off plastic Lionel 21" cars and it's super easy. I just used a box cutter with a fresh blade and followed the groove in the fluting making a couple dozen passes and then snapping it off.

I try to use this whenever possible, it works on just about anything.

Chris S.

I cut the skirts off some Kasner aluminum cars years ago using a router and table.  I mounted an abrasive cutoff wheel in the router and extended the table left and right  with particle board. I set the cutoff wheel to the depth I needed to cut off and clamped a 2 X 4 on to form a rip-fence to slide the car against.  I cut the skirt about .5mm long and then finished it off with a file.          j

Will - thank you for the tip. Haven’t checked yet on how I’m going to do it yet but this sounds better than the razor saw as long as I don’t jump the groove on the fluting lol   Ouch!

Al