This weekend I started to cut out the pieces for the body framework. One thing about Styrene is it is really easy to work with…you simply score it using five or six light pressure cuts, and flex it to snap it off along the score.
First, I roughly cut out the plan sections in preparation for sticking them on the plastic, then rough cut the plastic to the correct size…I’m glad I got the supplier to cut the sheets in half as trying to maneuver a 2.4m x 1.2m piece of plastic would have been a nightmare. Then I sprayed the back of the paper plan sections with the Bostik spray, and waited the two minutes or so for it to dry. Once it is dry, you simply place it on the surface to be stuck to, and smooth it down so there are no air bubbles between the paper and the surface. I find a cloth rag works fine for this.
One word of note when working with the plans. I looked at the base section, the one with three holes in parallel in the middle, and couldn’t marry up the stated cutting distances with the holes that I was thinking of using…use the middle hole, folks 
The others are to connect it to the other base plates below.
Then came the fun of using the routing table. I drilled a hole in the appropriate place on the plan/plastic sandwich, and then used a 3mm bolt to attach it to the pre-drilled hole in the table.
Then it is simply a matter of turning on the router and spinning the piece of plastic around the central pivot bolt.
The outer cuts take two steps, a rough step and a final step which smoothes out the rough cut. You will generate a STUPID amount of plastic shrapnel, so be warned…a vacuum cleaner sucking it up as you cut it would be a good idea (and as it is one that I have just had, I will have to use in the next session).
