A while ago I suggested (along with others) that cutting copper-clad,
photo-sensitized boards with a paper cutter type sheer was the way to go.  And
it is easy, and it does work, at least for larger boards.  I have since found,
however, that it does not work for cutting smaller pieces like 1.5 in. wide.
The damage to the resist is just too extensive -- as much as a third of the
board on each edge.

So, needing some way to cut boads 2 in. or 1in. wide, I turned to my trusty
Dremel drill press.  That is, I turned the drill head to its horizontal
position, and used a diamond cutoff wheel at about 80% speed.  Works like a
charm.  NO damage to the resist.

However, this wheel was expensive, and I have no idea how long it's going to
last.  I'm cutting 1/32 in. FR4, and I've only cut about 10 inches so far.

If you want to try this, here's what  to do:

1.  Switch the drill head to its horizontal mode, lever upward, bit forward, on
the left of the post.

2. Move the board, that's attached to the base of the drill press, forward so
it just clears the collar of the drill head.   You do have a board attached to
the base, right?

3. With the tool in the drill head, cut a groove in the board about 1/8 in.
deep with, say, a reinforced cutoff wheel.

4. Insert the diamond cutoff wheel and set the height so the edge of the wheel
is in the groove, just below the surface of the board.

5. Use a 3/4 in. or 1/2 in. long bolt, and the existing nut, to set the height.
Add a little bumper of some kind to the end of the bolt.  Set it tight enough
that it holds the height, but loose enough that you can still move it a little
side-to-side.

6. Chuck up a long 1/8 in. drill bit, like a drywall cutting bit, and square
that to your fence.  The fence can be just about anything you clamp to the
board.  Tighten down the bolt.

And that's it.

Cut resist-side down,
Colin

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