Expedition Exchange Bulletin Boards

Expedition Exchange Bulletin Boards (http://www.expeditionexchange.com/forums/index.php)
-   Technical Discussions (http://www.expeditionexchange.com/forums/forumdisplay.php?f=6)
-   -   what's your favorite tool for cutting starboard / seaboard (http://www.expeditionexchange.com/forums/showthread.php?t=832)

JSQ July 24th, 2006 02:58 PM

what's your favorite tool for cutting starboard / seaboard
In advance of the reflooring of the 110 cargo area I'm pondering how to get the best fit.

At the Rover Group my tech used a circular saw and got pretty good results.

what do you guys like best?

johnlee July 24th, 2006 03:10 PM

I used a circular saw for the square outer edges and a jig saw for the lashing cut-outs.

hochung July 24th, 2006 03:11 PM

circular saw for straight cuts and jig saw for irregular shap cuts.

JSQ July 25th, 2006 09:17 AM


steady hand too I suppose.

You guys think I should cut it slightly big and then sand it down to fit or just go for perfection on the first cut.

i'm worried that sanding can get too uneven too quickly.

johnlee July 25th, 2006 09:28 AM

When I started I tried to do the London Gun thing with cutting oversize and then sanding down to perfection. It didn't work for me. The sanding took far too long. If I had a power sander it might be different. But using 80-grit and a sanding block took forever. So on subsequent cuts I just tried to cut to perfection and my sanding was just to smooth out the serface.

nosivad_bor July 25th, 2006 12:49 PM

Ideally if you found a local shop that had a CNC water jet that would be the way to cut it. There is one right up the street from me that could do it.


JSQ July 25th, 2006 12:52 PM

Would a table saw be even better than a circular hand saw?

what are the advantages of the water jet Rob?

johnlee July 25th, 2006 02:14 PM

If the table saw is set up properly, you should be more likely to get perfectly square dimensions. I didn't have a table saw handy, so I had to measure length, width, and diagonally multiple times to make sure everything was square.

Water jet would be awesome. Perfect lines and minimal sanding too.

david July 26th, 2006 08:27 AM

a suggestion for the lashing cutouts...
when I did the flooring for the rrc rack, the flooring was so smooth that I had a difficult time controlling the jigsaw. The cuts looked crappy.
In hindsight, it would have worked better to put down some contact paper, layout and draw the circles on it, then use the jigsaw on top of the paper, for more friction and better control. I always learn the hard way.
For the straight cuts I used a straight edge clamped onto the starboard, and a carbide blade in the skil saw, no problems.

nosivad_bor July 26th, 2006 12:39 PM


Originally Posted by JSQ
Would a table saw be even better than a circular hand saw?

what are the advantages of the water jet Rob?

With a Water Jet you would lay the whole thing on a large table and all cuts would be made at one time. Everything would be square and perpendicular. Holes can be cut and nice radius in the corners. Water Jet is cold abrasive (sandy water) it will not warp the what it cuts and should basically deburr itself. A little sanding might be needed to make it totally smooth. The end result would be pretty darn nice though. My guess would be about $50-100 to cut it. Depending on the shops hourly rate. I would guess it would take about 1 hour to cut it. If you need it I can make you a cad drawing if it saves money. That would only take me 10 minutes to draw, and I would need a hand sketch.

Table saw I don't think would be that nice because you will have to move the entire piece of starboard to cut it. Circ saw you just have to move the saw along. The table saw if it was big enough the table had rollers wouldn't be too bad cause you can rid it along the rail to keep it straight, But man it would suck if it floated up and kicked back. I never liked cutting plywood on a table saw either.

Sorry if I ramble. :yappin:


alcruz July 27th, 2006 08:28 AM

Don't forget they typically charge a setup fee, then charge you the price to cut.

Jack if you need help with the CAD model or drawing I can help as well.....BTW, truck looks good!


traveltoad July 27th, 2006 09:13 AM


Originally Posted by alcruz
Don't forget they typically charge a setup fee, then charge you the price to cut.

Jack if you need help with the CAD model or drawing I can help as well.....BTW, truck looks good!


Hey Al! I haven't seen you in a while.

alcruz July 27th, 2006 09:35 AM

Been around, just not active. Damn priorities keep getting in the way :(

Hope all is well with you and the family :)

Oh Jack, it helps to create a template to insure proper fit before you go with any water jet process. If you have access to large scale plotter like Kinko's, have it plotted and use that as your template. Either way you can use the template for water jet or manual methods.


parantaeyang May 18th, 2007 05:51 PM

3 Attachment(s)
finally got the floor done on the SD rack. :D

Many thanks (especially, from the girls) to John and Ho for their time, space, tools, and guidance.

chris snell February 2nd, 2009 12:08 PM

Did anybody end up cutting their starboard with a water jet? This is the route that I want to take.

Also trying to figure out how to get a better ground plane for the antennas up on the rack. I was thinking about a 2' x 2' sheet of stainless steel, fastened to the underside of the starboard underneath the antenna

I ordered my SD roof rack from ECR today and it should be here in a few weeks.

dchapman February 2nd, 2009 12:28 PM

You should have held out and see what happens here. http://cgi.ebay.com/ebaymotors/Land-...Q5fAccessories

JimC February 2nd, 2009 12:52 PM

That's not stock, that rack looks like crap.

dchapman February 2nd, 2009 02:39 PM

Hmmm, I just looked at it again, and you're right that it's not a stock rack.

But I also have to agree with you about it looking like crap, too. I think all D-90's look like crap with the "stock" rack. To me, it looks like a grocery cart parked on top of the truck. It's just out of place. Kind of like a SD Highlander on a Discovery - I really do not like the look. The Lowlander looks great, but the Highlander...not so much.

All times are GMT -8. The time now is 05:48 PM.

Powered by vBulletin Version 3.5.4
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Copyright 2001-2012 Expedition Exchange Incorporated. All rights reserved.