Bakalite cutting and safty questions - Page 1
Forum section: electronics / projects

author: innkeeper
author_rank: Unknown
timestamp: September 14, 2017, 07:05:15 pm
content: I got my hands on an old NOS bakelite project box. I thought it would be a cool looking case for an electronic DC load.However when researching how to cut it properly i've learned that its full of large amounts of formaldehyde, asbestos and other extremely toxic polymers,I would still like to use this project box, but is there a safe way to cut holes in it.and if so, whats the best / safest ways to do that.or should i jsut put this thing in a plastic bag and treat it as hazardous waste

author: Benta
author_rank: Super Contributor
timestamp: September 14, 2017, 07:37:10 pm
content: Bakelite is normally harmless. But cutting it is an issue, as it cracks with very little provocation.

author: Ian.M
author_rank: Super Contributor
timestamp: September 14, 2017, 08:33:18 pm
content: From the safety point of view, its not really nasty, but the dust from formaldehyde resins isn't good for you so treat it like you would cutting any potentially toxic hardwood - wear a dust mask and goggles, cut it in a well ventilated area and either wipe the dust up with a damp cloth, gently sweep it up or use a vacuum with a HEPA filter to clean it up as soon as is practical.Personally I'd save a N.O.S. bakelite box for something a little more 'retro' than an electronic load. Maybe a valve radio or Nixie clock? As Benta pointed out, it can be brittle so isn't ideal for knockabout testbench projects.

author: mikerj
author_rank: Super Contributor
timestamp: September 14, 2017, 08:38:01 pm
content: Quote from: innkeeper on September 14, 2017, 07:05:15 pmI suspect you read this on a website which is absolutely loaded with incorrect, scary "facts", written by a rather odd person who promotes a certain alternative lifestyle.QuoteBakelite, just like other engineering polymers, can be loaded with filler materials to improve certain aspects of the material. Most bakelites used wood dust as a cheap filler, but asbestos was used when better heat resistance and toughness was needed. Just as with other asbestos materials, it only becomes a danger if turned into small particles (dust) and inhaled. To prevent the danger, simply ensure minimal levels of dust are produced whilst drilling by keeping the area being drilled wet.It is quite a brittle material however. Ensure the material is well supported directly under the point being drilled, and go slow.

author: Cerebus
author_rank: Super Contributor
timestamp: September 15, 2017, 12:10:26 am
content: Quote from: mikerj on September 14, 2017, 08:38:01 pmI'd go further. I'd suggest treating like glass or ceramics and drilling it at low speed with an abrasive diamond core drill sold for drilling glass or ceramics. A slow stream of water will both deal with any dust problem and keep the cutter cooled.

author: Gyro
author_rank: Super Contributor
timestamp: September 15, 2017, 09:24:29 am
content: I keep a cheap diamond tile saw kicking around for wet cutting abrasive materials, FR4 etc. That way most of the dust ends up in the water bath and is easy to rinse out, or stays wet on the surface and can be wiped off. The plastic fence is good enough for keeping things square.eg.https://www.toolstation.com/shop/p10565?table=noWorst case, you can do some diy and trim some wall tiles with it!

author: grumpydoc
author_rank: Super Contributor
timestamp: September 15, 2017, 10:15:07 am
content: Quote from: Gyro on September 15, 2017, 09:24:29 amI bought one of those (not from Toolstation though) to cut tiles rather than anything elseUseless piece of utter crap.