Meet the Dremel

Now we replace our flexshaft accessory and our cutting wheel with our grinding stone bit. This is the perfect tool for the job. Sanding wheels do a good job but usually wear out too fast for my liking. I ditched the flexshaft and worked with the actual dremel tool for this because I prefer the substantial grip you get with the motor section as opposed to the flexshaft. Steady hands and a small amount of force is the key. This is really where the masking of the area with tape and working on the opposite side of the surface comes into play. If you are going to slip and scratch the surface, you\'re more likely to do it on the side facing you rather than the bottom side. Here it is after a portion has been ground. You can really tell the difference, not perfection but certainly safe for hands.


I take a breather and let youth take over... tired of the creditless job of photographer the 11 year old gets into the act. Patience young jedi...


Looking purdy good.... certainly with a grill on this is done...


But for perfection, one could work with the grind stone a little more or for a really refined look, need to move onto the old fashioned way... filing... I really don\'t mind the help at this point but he gave up soon and I had to finish out the hole. He\'s got the raw passion and talent but not the commitment... especially since this isn\'t for a case that will be sitting on his desk.


After a bit of filing we get the hole down to some nice quality. Left is the other side, virtually unscathed outside the hole. The bottom pic is with the original grill we used as a template. Not bad, especially for material so thick.