I was looking for a method to cut Nomex honeycomb along the profile. I have some 1" thick raw panels (not bonded to any facing) that I would like to “fillet” into 1/4" -3/8" ribs to work with a current project.
band saw, bread knife?
I thought of filling the cells with a-b foam to make the panel more rigid for cutting but I would rather keep the cells open if possible.
we use to cut 30mm honeycomb core so that it would taper to 20mm on one end, and 8mm on the other. We made a cheap wooden jig that attached to the table saw, didnt look pretty, but it cut it just as well as the ones we would purchase precut direct from the factory.
I’ve used a core knife…which was a VERY SHARP steel blade. I would hold at an angle off a table, and trim carefully.
I jig would work too if you have the ability.
I also used 300g sand paper with an orbital palm sander if the angles had to be more accurate.
But yeah…jigs, and a sharp blade should work.
Hey 1off:
If you don’t need to save the other half of the honeycomb a
milling machine would work. This would also give you good
thickness control.
I have used an exacto knife but it was a small part. I used
the sanding plane on it to smooth it out after wards.
Jim
A mill with the proper cutter works very well. Must use high rpm.
Sorry for the bad pic, but the machine was moving towards me!
Thank you for all the help. I ended up using a 10" band saw with a piece of mdf on the fence and another with foam tape (held firm the cells) to push it through. Took a bit of set up but worked very well.