never expect the dremel to make the perfect corner. use files to do up the corners. another thing that you may want to bear in mind is the cutting rotation direction, then nearing a corner you might want to cut with the dremel rotating in a direction that cuts by spinning upwards to the cut... not downwards... hrmm... how to explain that... like u know, the dremel spins clockwise with the handle facing u...when cutting towards the right hand side direction, it has a tendency to climb up the surface being cut, thus possibly causing overshoots or grinding unto unwanted surfaces. whereas if you're cutting towards the left hand side direction, the dremel digs in; it will never climb up. I normally do this when nearing a corner.

I normally don't mind which cutting direction on long straight lengths except when I'm cutting intricate stuff, I always cut towards the left to prevent overshoots and jumping/climbing mistakes. bear in mind that when cutting this way, you will have lots of dust and shards flying upwards. make sure you have goggles/specs and a breathing/face mask. aluminium or steel dust ain't exactly healthy to breathe in.

This post has been edited by MetalZone: Jun 11 2007, 03:38 PM