Carving polystyrene with a hand-held saw can be a bit challenging, but it can be done with some patience and the right tools. Here are some steps to follow:
- Choose the right saw: Use a fine-toothed saw with small teeth. A coping saw or a hacksaw with a fine blade works well. Avoid using a serrated blade, as it will tear the polystyrene.
- Plan your design: Draw your design on the polystyrene using a marker or pen. Make sure the lines are straight and accurate.
- Secure the polystyrene: Hold the polystyrene in place using a clamp or a vice. This will help keep the material steady as you work on it.
- Start cutting: Begin cutting along the lines of your design using the saw. Use light, gentle strokes, and avoid applying too much pressure, as this can cause the polystyrene to break or deform.
- Follow your design: Continue cutting along the lines of your design until you have carved out the desired shape. Take your time and be patient, as polystyrene can be brittle and delicate.
- Smooth the edges: Once you have finished cutting, use sandpaper to smooth out any rough edges or imperfections. You can also use a hot wire cutter or a heat gun to melt and smooth the edges, but be careful not to apply too much heat, as this can melt the polystyrene.
Remember to wear safety goggles and a dust mask while working with polystyrene to protect your eyes and lungs from any fine particles that may be produced during the cutting process.