domecutting

This is a method of cutting the dome panels out completely. You will need an "inner" dome for the panels to rest on. So this method uses 2 domes to make one.

Have your dome marked off and ready to cut. Make sure it is how you want it, once you start cutting there is no going back.

Next is to locate where the holes and cutouts will be on the dome. 2 PSI holes, 3 holoprojector holes, 2 front display boxes (rectangular), and 1 rear display box (rectangular).

It is important to cut these areas out before you remove the panels that they are located on. It is easier to work on the holes when still attached to the dome.

For the circle holes I used and adjustable hole cutter to score the dome surface. (see below)

Then using a Jig saw, I cut "tabs" inside the hole area. (pictured at the right). Using some pliers I snapped off the "tabs" and then filed the holes smooth. This is an easier way to make the holes with out trying to go all the way through the dome with the adjustable hole cutter.

The next step is to use the dremel with a "saw blade" tip to make a slot the jig saw blade can fit through.

(saw blade tip shown below).

In the picture at right I have circled in red the hole made by the dremel. I can now slip the jig saw blade in the hole and make a nice straight cut. You will need to make a slot on each side of each panel to be removed. This will leave you with no waste and reuseable panels.

I cut out all the bottom panels first, filing each panel and each panel hole as I worked. This removed all the sharp edges as I handled the dome. Next, I cut the top circles out and finally the upper pie panels. Do these last because the dome begins to get weak around the pie panels.

Below is a dome with all the panels cut out.