Any tips on cutting bakelight?

[Spark plug]

I've got a sheet of 8mm bakelight to cut up to go In the sides of a trailer and it's proving difficult, hand saw didn't get an inch before it was blunt, jigsaw with metal blade didn't help just overheated the blade, circular saw ran away in fear with it TCT blade for aluminium Bettwen it's legs.

Any one got any ideas?

 

[bill_gj]

You sure it is just Bakelite? It's just a thermo-setting resin after all. Years ago, I often got given jobs to make from similar materials without too much bother.

 

[Spark plug]

It looks like bakelight but could be some other Formica type hard plastic.

It seems to splinter and come off in lumps more than cut.

 

[BrokenBiker]

im sure ive used a normal 32tpi hacksaw blade to cut it before.

could be different though there are hundereds of plastics out there

 

[Spark plug]

im sure ive used a normal 32tpi hacksaw blade to cut it before.

could be different though there are hundereds of plastics out there

That would probably work but I have about 25' of cutting to do.

 

[Spark plug]

Anyone tried abrasive/diamond discs for this sort of thing?

I would think it would burn rather than cut, but willing to try anything now.

 

[BrokenBiker]

can you use some cutting fluid coolant on the jigsaw blade, water would do the job, just a trickle over the blade should keep it cool enough to cut

 

[wheresmejumper]

An aluminium cutting disc in a grinder, shouldnt load up too bad

 

[MattF]

It's unlikely to be Bakelite. They stopped making that stuff donkeys years ago, as far as I know. It's more likely to be some fibreglass/resin combo.

Any fine blade should cut it okay. Jigsaw would be my first thought. Just take it steady and let the blade cut rather than forcing it.

 

[octo0072000]

angle grinder with a thin cutting disc give it a try

 

[brightspark]

bakerlite has asbestos in it

angle grinder with a thin cutting disc give it a try

try a metal cutting disk 1st and if not a stone one, as they will cut metal as well as stone

 

[MattF]

bakerlite has asbestos in it

Just on a tangent now that you've jogged my memory with that sentence, (Bakelite being commonly used for switch housings and Asbestos being flame retardent, if anyone's wondering about the logic ), is there any reg or such against using wood for an enclosure for mains switches? Example: you have a toggle switch switching a mains voltage and enclose it totally in a wooden box, including wooden front panel to which the switch is mounted.

 

[bill_gj]

SOME Bakelite products may have asbestos in them (parts where highly heat resistant properties are required), but the great majority won't have. Products made from phenolic resins generally didn't have any fillers or fibre reinforcements.

What colour is this stuff you are trying to cut, any clues there?

MattF is right in saying that big sheets are not going to be Bakelite, unless you found it in a derelict electrical/electronics factory from the Second World War. Phenolic resins are still used for lots of products but big sheets are stronger and cheaper made from other materials.

Is it a tan / light brown colour? Any fibres visible? It could be SRBP (synthetic resin bonded paper).

 

[brightspark]

Just on a tangent now that you've jogged my memory with that sentence, (Bakelite being commonly used for switch housings and Asbestos being flame retardent, if anyone's wondering about the logic ), is there any reg or such against using wood for an enclosure for mains switches? Example: you have a toggle switch switching a mains voltage and enclose it totally in a wooden box, including wooden front panel to which the switch is mounted.

mem used to make fuseboxes from wood with porcelane fuse and carriers and bakerlite main switch. any new equipment has to be enclosed in either metal or a self extinguishing plastic enclosure. namely fireproof .

 

[gordon stephenson]

Most likely the material is Tufnol, Excellent electrical insulation, they made 2 main types, I think they were called "crow" and "kite" One was made from highly compressed resin soaked linen the other was resin soaked paper, The linen one is sort of a tan colour, and you can still see the woven material on the face of the sheet, The paper type was dark brown.Usually cut with a jigsaw or hacksaw, the use of dust extraction should be used

 

[bill_gj]

TUFNOL !! The name I couldn't remember and a smell during cutting you don't forget.

 

[piman]

Hello all,
Tufnol is easily cut however, it wouldn't blunt a band saw or jigsaw blade?

Alec

 

[Spark plug]

It's new stuff a friend got a pile of it from some ware. It's got a light brown / tan core with a blue finish either side, it's smooth either side, increadably strong and rigid.

Not sure about if you can see any fibers ile have a look tomorrow.

 

[MattF]

mem used to make fuseboxes from wood with porcelane fuse and carriers and bakerlite main switch. any new equipment has to be enclosed in either metal or a self extinguishing plastic enclosure. namely fireproof .

Cheers. It is quite feasible to use wood then, when building enclosures for ones own equipment?