Cutting Styrene

[Horrorshow]

I’m planning a couple of builds that require extensive cutting to the chassis. Any recommendations for the best tools and techniques?

[Fat Brian]

I keep a deep blade razor saw for long, straight cuts. I also use Model Car Garage photoetch saws for tight areas and curved cuts. However, one of the most important tools in my cutting arsenal is a set of digital calipers. Making even, straight cuts saves a ton of trimming and truing up after the fact.

[bobss396]

I have a few razor saws that I use all the time. They hang in unless you are cutting hard materials.

I agree on the MCG PE saw blades, very flexible and hard-ish to break.

I have an upcoming project where I'll be grafting some 3D printed items into an existing chassis or possibly making a whole new chassis.

I have rough-cut chassis stubs off before and used my Bridgeport mill to cut the rest off squarely and accurately. I hold the chassis/floor pan in the vise.

It is always fun putting things back together keeping them square and parallel, etc. I use graph paper and a steel scale for most of that. I had taped a piece to  some 1/8" steel stock and used magnets (cabinet catch parts) to block it up so I could tack-glue it together.