best way to edge a plastic blade

Belt sander? How long is the blade? I did that on a Klingon Dk'Tagh I started years ago, and it came out great, but the beveled areas on one of those are fairly short.

-Sarge
 
Belt sander? How long is the blade? I did that on a Klingon Dk'Tagh I started years ago, and it came out great, but the beveled areas on one of those are fairly short.

-Sarge

LIGHT TOUCH on the sander. That plex will vanish like dust. Then smooth it with a medium ******* file. The finer you want, the most you wet sand.
 
Yeah, kinda what Jax said.

I've seen flame polishing and while it's good for some things it's not right for this especially if you want to paint it. A smooth surface gives the paint nothing to hold onto.

The plex knife I made.

plexiknife0.jpg


plexiknife4.jpg
 
that's exactly what i mean, a very straight edge which doesn't look like it was filed/sande by hand. How did you do the edge on that killer klingon blade?
 
I used rat tail files, sandpaper glued to a block of plastic, a steady hand, and as with all projects...patience and unrelenting persistance. Keep in mind your timeframe to completion is that it will be done when it is finished so enjoy the journey as well. Unfortunately it is easier shown than explained in words.

The pieces were all laser cut. It was edged by hand. First draw where you want the edges to be. Knock down the bulk of it with a dremel but do not reach the guidelines you just drew. Use the files to get in closer and finally the sandpaper block to make a uniform flat surface.
 
Loads of elbow grease and patience is the way to go :thumbsup

I use my power tools very sparingly, as I prefer the precise control hand tools offer...
 
If you glue two equaly thick pieces together to make the total thickness you need, you will always have the seam line between the plates to guide your edge. no matter what you do to the edge that line will always be exactly half of the total thickness of the blade. it will make it a lot easier to sharpen each side equaly.
 
Flame polishing will remove the sharp edge.

I used to be the flame polisher of a aquarium manufacturer.
Same company that made Picards Bubble Tank in his Ready Room.

It's used to dull the razor sharp edges and give it a shine without all the sanding.
Has to be done fast or it will burn the plex.
If that happens then you have to do LOT'S of sanding.

D6
 
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