Easy 45 Degree Bevel Tool

Unlike Josh and the rest of the FliteTest crew most of us do not have a steady hand when cutting with a razor blade.  Especially when it comes to the control surface bevel.  I personally always cut too little or too much but never the right amount. With this problem presenting itself on every foam model I have made I figured there was an easier way. 

I wanted to develop a tool that was easy to make and definitely easy to use.  The tool is very simple in its design and is focused around the readily available number 11 hobby knife blade.  The tool consists of the main body that holds the blade in place at the 45 degree angle and the proper 3/16” depth for the perfect cut. A cover piece finishes the assembly capturing the blade for safety.

The tool was designed in SolidWorks 3D cad software and can be 3D printed using any FDM (fused deposition modeling) style printer.  I am fortunate to have access to one of the Stratasys printers at work.  I am including the .stl and .step files so that you can print the model as well.  I have also included a foam core board version if you do not have access to a 3D printer.

Plastic 3D Printed Version Setup and Instructions:

Once the tool has been 3D Printed it may require depending upon your printers tolerances some “work in” to open the blade slot.

I would recommend the following steps for inserting the blade:

• For best results use a new sharp number 11 hobby knife blade.
• With the blade still in the hobby knife insert the blade with the sharp edge toward the left of the tool(cutting right to left). Note the base of the cutter will have the guide/ guard away from you pointing to the floor.
• Press firmly until the blade is seated into the vertical guide/guard.
• Remove the blade from the hobby knife.
• Slide the cover over top of the end of the blade capturing the blade entirely in the device.  Note the cover should come in contact with the tools main body.

To use the 45 degree bevel tool do the following steps: 

• With the blade mounted and captured in the bevel tool rest the tool firmly against the edge of the foam board at the right end of the edge you wish to bevel.
• Usually hanging the board over the edge of your work space work best as to keep the cutter path free.
• Make sure the foam board is full engaged into the corner of the tool guide/guard.
• With even speed and pressure cut along the edge of the board.
• Enjoy your straight and evenly cut bevel.

Foam Core Setup and Instructions:

Construction of the foam core version of the tool is as follows:

• Cut out the foam core profile from the pdf provided.
• Use the glue sparingly as you do not want any excess of glue on the inside corner of the tool.
• Use an A fold technique to glue the short leg above the long leg of the tool.
• Reinforce the outside of the tool with packaging tape.
• Verify the tool is at a right angle at the inside corner.
• Insert the hobby knife blade at a 45 degree angle so that it leaves a 3/16” equal spacing from the corner to both points where the blade meets.  Use the sketch location on the drawing for reference.
• Add a drop of hot glue on the blade’s hobby knife end so that the blade is secured in the tool.

To use the 45 degree bevel tool do the following steps:

• With the blade inserted in the foam core cutter rest the tool firmly against the edge of the foam board at the right end of the edge you wish to bevel.
• Be careful as to not have the knife blade move in the cutter tool holder.
• Usually hanging the board over the edge of your work space work best as to keep the cutter path free.
• Make sure the foam board is full engaged into the corner of the tool guide/guard.
• With even speed and pressure cut along the edge of the board.

I hope you found this article insightful and useful.  Please download and use the design.  I am sure you find this an easy alternative to cutting a bevel free hand.

45 Degree Bevel File Set