I need to find the proper power tool - any ideas or suggestions?

**Dodgy Dovetails** · 20th August 2015, 06:05 PM

I have to send a lot of fragile prints in the mail and to protect them I cut two A4 size cardboard inserts from fruit boxes to reinforce the envelope.

These fruit boxes have to transport food, and so they are manufactured as the last word in cardboard structural integrity. So they are also ideal to transport my own fragile items.

Here is one of the boxes I cut from (getting two A4's per box) and next to it is the resulting neat little pile of inserts to include in my envelopes.

However, the boxes' very structural integrity makes them quite tough to cut through.

I bought a cutting tool over three years ago and it has performed reasonably well since then, although the jaws would still consistently become clogged with cardboard and its cutting ability regularly highly reduced. You can see in the photo the random jagged cuts that results when this happens as, in frustration, I use main force to drive the tool through it anyway. Now I know this is the kind of tool abuse that all of you recoil from,

but hey! my reasoning is that I'm one in charge here, not it, and so I'll decide if it is going to cut - not it.

Here is the cutting tool:

The problem of course is that it is just not the right tool for the job. Even so, it has still endured more than three years of my abuse before justice (and material fatigue) finally reared its ugly head. The plastic that locks the lower jaw in place split, so that its jaws ended up up gaping like a boa trying to swallow an antelope:

I really need a proper cutting tool more dedicated to the job in hand. I have to do a lot of these boxes and cutting them manually with a stanley knife is murder as they are very meritoriously strongly made cardboard. I don't want to re-live the deficiencies of the last few years either by getting another of the former cutting tool.

Here is my drawing of what I'd really like to find:

I can imagine this whirling blade slicing though the boxes with just one throw of the wrist, with almost as little resistance as (my ideal) a hand held laser.

So does anyone have any ideas or suggestions to what is out there that may fit my hopeful design or be adaptable to it?

Thank you.

**A Duke** · 20th August 2015, 06:28 PM

Hi,
Dremsaw.jpgMaybe?
Regards

**Handyjack** · 20th August 2015, 06:45 PM

http://www.bunnings.com.au/bosch-190...tool-_p6200444
You could try a multi function tool.

With the correct set up another possibility is a router with a straight bit.

Let us know how you go.

**Bob38S** · 20th August 2015, 08:15 PM

The Dremel saw should work well, alternatively, the Dremel router attachment with a straight bit would give you 2 handed stability.

Just a thought.

**ian** · 20th August 2015, 10:40 PM

thoughts

band saw with zero clearance throat plate.

heavy duty rotary cutter

table saw with zero clearance table insert and very fine blade

jig saw with a cardboard cutting blade -- but I can't find what blade to recommend

**iolithblue** · 20th August 2015, 11:34 PM

http://www.gettoolsdirect.com.au/bos...tAphoC_ELw_wcB

**rob streeper** · 21st August 2015, 07:11 AM

Tried a drywall saw?

**Quinny01** · 21st August 2015, 08:11 AM

I remember having knife blades for a jigsaw years ago. Looking online I found this.

http://www.valutool.com/BOSCH-JIGSAW...-saw-blade.htm

Mean looking thing,but about right for what you need I think.

Quinny

**Dodgy Dovetails** · 21st August 2015, 08:20 PM

Originally Posted by rob streeper

Tried a drywall saw?

Thanks for the idea, but I'm trying to avoid anything too manual - I need battery assist.

Thanks everyone, I will research these options further and let you know the results.

**FenceFurniture** · 22nd August 2015, 10:12 AM

Originally Posted by ian

jig saw with a cardboard cutting blade -- but I can't find what blade to recommend

I should think that any old jig saw blade would probably work Ian. Maybe start with a metal cutting blade, and change to something else if required. Or go for the "Composite material" blade.

DD, the advantage of a jig saw (as I see it) is that you could cut several sheets at once. You might want to hold the small stack of sheets with a couple of spring clamps or similar.

EDIT: get an old jig saw blade and grind it down to a knife edge. The local mechanic should have a suitable grinder.

**Wizened of Oz** · 22nd August 2015, 11:50 AM

I would think you would save time and money by simply buying A4 cardstock in bulk.

**ian** · 22nd August 2015, 01:44 PM

Originally Posted by Dodgy Dovetails

Thanks for the idea, but I'm trying to avoid anything too manual - I need battery assist.

Thanks everyone, I will research these options further and let you know the results.

Originally Posted by Quinny01

I remember having knife blades for a jigsaw years ago. Looking online I found this.

http://www.valutool.com/BOSCH-JIGSAW...-saw-blade.htm

Mean looking thing,but about right for what you need I think.

recommend the knife edge jigsaw blades

**godzilla73** · 23rd August 2015, 10:16 PM

G'day, give a bindery mob a call about getting card cut to size on their guillotine. It would literally take them under a minute to cut an A1 sheet to the sizes you require. Even a smaller printing company with a guillotine would be able to handle it.

**Dodgy Dovetails** · 24th August 2015, 12:30 AM

Originally Posted by godzilla73

G'day, give a bindery mob a call about getting card cut to size on their guillotine. It would literally take them under a minute to cut an A1 sheet to the sizes you require. Even a smaller printing company with a guillotine would be able to handle it.

The fruit boxes are manufactured to the highest strength standard because they have to transport fragile food. What I send is even more fragile. There is nothing else that comes up to the structural strength of the fruit box cut outs. The post can be hard on fragile items, and rarely they have even managed to damage the prints even with the inserts. So it makes me wonder how many the high standard of protection has saved from this!

But with some of the great ideas I've got (with much gratitude) from here, I think I'll be able to whiz through cutting the boxes in a third of the time!

**yvan** · 24th August 2015, 08:23 AM

Why not contacting Visy to find out if the cardboard you need can be purchased before it is made into fruit boxes and then hae it guillotined into the size you need? Unless cost is a major issue?

Yvan

Thread: I need to find the proper power tool - any ideas or suggestions?

Thread Tools

Search Thread

I need to find the proper power tool - any ideas or suggestions?

Similar Threads

2014 Australia Day Pen Swap - Suggestions and Ideas

H-E-L-P,- Ideas and suggestions please !!!

Useful Ideas, & helpful suggestions please

Proper name for this tool

Posting Permissions