Estes Klingon Battle Cruiser, #1274, Build Part 2, Vacu-Form Parts Cutting

Many builders run into problems cutting vacu-form plastic pieces off the sheet.
The main points to remember are - take your time, use a new blade and don't try to cut through with a single pass of the knife.
Normally I'd use my break off blade knife but for this I'll use the X-Acto with a new #11 blade. The Estes instructions say to use your hobby knife or a single edge razor blade. These parts would be very hard to cut out with a razor blade.

You'll need the flat edge from the vacu-form sheet for the hanger side piece base later on.
It says "At least 11/16". Cut as wide as you can without getting into the Bridge Halves pieces.

Vacu-forming stretches a thin sheet of heated, softened plastic over the master form. The taller the piece, the thinner the plastic will be. The highest sides of the primary hull pieces (nose section) are pretty thin.

Start by tracing around the edges with a ball point pen. This gives a good contrast line to cut on.


For practice, cut a piece with straight lines first.
Cut beyond the piece for an easier "flex and crack" separation of the outside edges.
Use light cuts, three or four passes. Keep your knife at about a 45 degree angle so you have no chance of cutting into the finished piece.
Follow up is in the next post -