I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

I know I will not be using a grinder (with a cut off wheel) because I
cannot see how I can keep the dust down using it.

My circuit saw doesn't have a dust port. Would the result be much
less dusty if the circuit saw had a dust port? If it will be less
dusty with a dust port, it will be my first choice because I can cut
very straight using a circuit saw. But I doubt it because I have a
feeling that all the rotary tools kick up a lot of dust and will be
hard to control dust.

Is a jig-saw much less dusty? I know I would have a hard time using a
jig saw to cut at 45 degree angle. But this should not be a problem
because I am cutting at a 90 degree angle anyway. I may have a hard
time to cut a straight edge using a jig saw. But I think I can fix
this by using a straight wood board to guide the jig saw.

Is a reciprocating saw less dusty? Then I can use it to cut at any
angle, like what the guy in ShipShape TV used to cut a hole on the
floor of a boat and keep the cut edge at a 45 degree angle. But I
have a feeling that I would have a hard time to keep the cut edge
straight using a reciprocating saw.

Any other better power tool? I welcome any suggestion and experience
that people want to share.

Thanks.

Jay Chan

How thick is the deck? I cut off deck top with a dremel. Thin kerfs,
straight lines, little dust.

Terry K

Jay Chan wrote:

I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

I know I will not be using a grinder (with a cut off wheel) because I
cannot see how I can keep the dust down using it.

My circuit saw doesn't have a dust port. Would the result be much
less dusty if the circuit saw had a dust port? If it will be less
dusty with a dust port, it will be my first choice because I can cut
very straight using a circuit saw. But I doubt it because I have a
feeling that all the rotary tools kick up a lot of dust and will be
hard to control dust.

Is a jig-saw much less dusty? I know I would have a hard time using a
jig saw to cut at 45 degree angle. But this should not be a problem
because I am cutting at a 90 degree angle anyway. I may have a hard
time to cut a straight edge using a jig saw. But I think I can fix
this by using a straight wood board to guide the jig saw.

Is a reciprocating saw less dusty? Then I can use it to cut at any
angle, like what the guy in ShipShape TV used to cut a hole on the
floor of a boat and keep the cut edge at a 45 degree angle. But I
have a feeling that I would have a hard time to keep the cut edge
straight using a reciprocating saw.

Any other better power tool? I welcome any suggestion and experience
that people want to share.

Thanks.

Jay Chan


I think I'd try the jig say or a hand saw.

The swarf would be quite large - not dust at all.

Richard

On Wed, 17 Oct 2007 07:38:21 -0700, Jay Chan
wrote:

I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

I know I will not be using a grinder (with a cut off wheel) because I
cannot see how I can keep the dust down using it.

My circuit saw doesn't have a dust port. Would the result be much
less dusty if the circuit saw had a dust port? If it will be less
dusty with a dust port, it will be my first choice because I can cut
very straight using a circuit saw. But I doubt it because I have a
feeling that all the rotary tools kick up a lot of dust and will be
hard to control dust.

Is a jig-saw much less dusty? I know I would have a hard time using a
jig saw to cut at 45 degree angle. But this should not be a problem
because I am cutting at a 90 degree angle anyway. I may have a hard
time to cut a straight edge using a jig saw. But I think I can fix
this by using a straight wood board to guide the jig saw.

Is a reciprocating saw less dusty? Then I can use it to cut at any
angle, like what the guy in ShipShape TV used to cut a hole on the
floor of a boat and keep the cut edge at a 45 degree angle. But I
have a feeling that I would have a hard time to keep the cut edge
straight using a reciprocating saw.

Any other better power tool? I welcome any suggestion and experience
that people want to share.

Thanks.

Jay Chan


Look at it this way. If you cut the deck off you will be removing X
amount of material - the width of the cut times the length of the cut
so you can control only the composition of the result not the
quantity. A grinder with a cut-off wheel will produce the finest
material while a saw with very coarse teeth will produce the coarsest.

One thing to think about if you use a saw of some sort is that
fiberglass is very abrasive to cut and you may need more then one saw
blade.


Bruce-in-Bangkok
(Note:displayed e-mail
address is a spam trap)

Bruce in Bangkok wrote:
On Wed, 17 Oct 2007 07:38:21 -0700, Jay Chan
wrote:

I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

Having done some _major_ surgery on my boat (cutting many many feet of
fiberglass/foam core deck and hull) I have a bit of experience in this.

A jigsaw or reciprocating saw with a carbide grit blade will be your
least dusty option. A angle grinder with cutoff wheel will be your
worst; a circular saw with a carbide blade will be in between. A
chainsaw is fast, but you'll go through lots of expensive chains. I
tried them all.

You will use many blades. I figured a carbide grit blade on my jigsaw
was good for about 10' before it was scrapped. Glass is hard to cut.

There is also a pro boat building air tool that uses a housing around
a cut off wheel and grinder, and hooks to a vacuum, but for a single
project it would probably be too costly.

Get yourself a good white bunny suit and tape up well. Use lots of
talcum powder on exposed skin. Have a cold shower afterward. Try to
do it all on one day so you don't have to repeat the exercise of being
itchy again.

Evan Gatehouse

Subject

A chop saw cut off blade in a Skil saw will produce a clean, but VERY
dusty solution.

What ever you do, protect your lungs.

Lew

On Oct 17, 10:38 am, Jay Chan wrote:
I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

I know I will not be using a grinder (with a cut off wheel) because I
cannot see how I can keep the dust down using it.

My circuit saw doesn't have a dust port. Would the result be much
less dusty if the circuit saw had a dust port? If it will be less
dusty with a dust port, it will be my first choice because I can cut
very straight using a circuit saw. But I doubt it because I have a
feeling that all the rotary tools kick up a lot of dust and will be
hard to control dust.

Is a jig-saw much less dusty? I know I would have a hard time using a
jig saw to cut at 45 degree angle. But this should not be a problem
because I am cutting at a 90 degree angle anyway. I may have a hard
time to cut a straight edge using a jig saw. But I think I can fix
this by using a straight wood board to guide the jig saw.

Is a reciprocating saw less dusty? Then I can use it to cut at any
angle, like what the guy in ShipShape TV used to cut a hole on the
floor of a boat and keep the cut edge at a 45 degree angle. But I
have a feeling that I would have a hard time to keep the cut edge
straight using a reciprocating saw.

Any other better power tool? I welcome any suggestion and experience
that people want to share.

Thanks.

Jay Chan


Thanks for everyone who has replied. I appreciate that.

Because the deck is relatively thick (like slightly more than 1/2"), I
doubt that a dremel will be able to handle this. But this gives me an
idea. May be I can use a router with a straight cut bit. I didn't
think of that. I have a router that has a dust port and transparent
plastic covers blocking all the openings. I "think" it may do a good
job in collecting all the dusts that the router. The downside is that
I am "very" sure that it will generate a ton of dusts and may clog the
filter in my shop vac very quickly. Therefore, I am very hesistate to
try this. At the end, I think I will pass.

I went to Sears to check on their circular saw, and I cannot find any
that has a dust port. I guess the idea of putting a dust port in a
circular saw doesn't work quite well. I remember my circular saw
kicked up a lot of dusts when I used it to cut a small area of the
floor. I think I will not try it again.

Seen like I should use a jig saw with several new carbide saw blades.
In areas where the floor is resting on a stringer, I will not be able
to use a jig saw. For those areas, I will have to use a hand saw or a
reciprocating saw.

Of course, I need to wear a protective suit, gloves, face mask, and
tape around all openings. And thanks for the tip of taking a "cold"
shower instead of a warm one (I didn't think of that).

Thanks again for the tips and for sharing your experience in this
issue.

Jay Chan

"Jay Chan" wrote:

May be I can use a router with a straight cut bit.

Forget it, the dust will destroy a router in maybe 20 minutes, if you
are lucky.

Lew

Jay Chan wrote:
On Oct 17, 10:38 am, Jay Chan wrote:

I am about to cut out the whole fiberglass deck from my boat. I
remember that was a very dusty job when I cut an area of the floor
using a circuit saw and a grinder (with a cut off wheel) even with a
shop vac pointing at the cutting area. I would like to find a less
dusty way of cutting the floor using a power tool.

I know I will not be using a grinder (with a cut off wheel) because I
cannot see how I can keep the dust down using it.

My circuit saw doesn't have a dust port. Would the result be much
less dusty if the circuit saw had a dust port? If it will be less
dusty with a dust port, it will be my first choice because I can cut
very straight using a circuit saw. But I doubt it because I have a
feeling that all the rotary tools kick up a lot of dust and will be
hard to control dust.

Is a jig-saw much less dusty? I know I would have a hard time using a
jig saw to cut at 45 degree angle. But this should not be a problem
because I am cutting at a 90 degree angle anyway. I may have a hard
time to cut a straight edge using a jig saw. But I think I can fix
this by using a straight wood board to guide the jig saw.

Is a reciprocating saw less dusty? Then I can use it to cut at any
angle, like what the guy in ShipShape TV used to cut a hole on the
floor of a boat and keep the cut edge at a 45 degree angle. But I
have a feeling that I would have a hard time to keep the cut edge
straight using a reciprocating saw.

Any other better power tool? I welcome any suggestion and experience
that people want to share.

Thanks.

Jay Chan



Thanks for everyone who has replied. I appreciate that.

Because the deck is relatively thick (like slightly more than 1/2"), I
doubt that a dremel will be able to handle this. But this gives me an
idea. May be I can use a router with a straight cut bit. I didn't
think of that. I have a router that has a dust port and transparent
plastic covers blocking all the openings. I "think" it may do a good
job in collecting all the dusts that the router. The downside is that
I am "very" sure that it will generate a ton of dusts and may clog the
filter in my shop vac very quickly. Therefore, I am very hesistate to
try this. At the end, I think I will pass.

I went to Sears to check on their circular saw, and I cannot find any
that has a dust port. I guess the idea of putting a dust port in a
circular saw doesn't work quite well. I remember my circular saw
kicked up a lot of dusts when I used it to cut a small area of the
floor. I think I will not try it again.

Seen like I should use a jig saw with several new carbide saw blades.
In areas where the floor is resting on a stringer, I will not be able
to use a jig saw. For those areas, I will have to use a hand saw or a
reciprocating saw.

Of course, I need to wear a protective suit, gloves, face mask, and
tape around all openings. And thanks for the tip of taking a "cold"
shower instead of a warm one (I didn't think of that).

Thanks again for the tips and for sharing your experience in this
issue.

Jay Chan


I haven't set this up yet, but next time I'm doing this kind of work
I'll give it a try.

Another sealed 5 gallon bucket (with connectors for in and out hoses) is
filled half full with water. The inlets hose fitting extends just below
the water surface. This mess gets plumbed upstream of the shop vac.


The fellow across the pier showed me his home brewed set up.
AND the water after sanding inside his boat.

Anything that traps that much fine dust has got to be worth a try.

Richard

Before you take a shower, use masking or packing tape to pull off f/g
dust. This provides a measure of relief I find difficult to describe
in sufficiently glowing terms. An adhesive style lint and hair
roller / brush is OK, but a lot more money.

Terry K