I wanted to chop the IMEX 1/16 scale Rat Rod pickup cab and doors. I landed on an idea of how to hold the pieces together securely and cut them as a unit.
I taped the pieces together and marked the top and bottom cuts. I placed the body (with the doors still taped in place) in a soup bowl filled with water to the level of the top cut mark, then placed the bowl in the freezer. After the water froze, I cut the body and doors across the ice with a razor saw.
I thawed everything out, put the body back in the bowl on a small wood shim the width of my total chop, and refroze the bowl. A second cut across the ice with a razor saw was performed, and the chop came out dead level and required almost no sanding or filler.
While the water freezes, hold the body onto the bottom of the bowl with a weight to ensure that the body is level. The ice holds the plastic so solidly that the styrene doesn't deflect when it's being cut, so the cuts are ultraprecise and the parts fit almost perfectly.
Anything with sloped pillars may require the body to be positioned or secured and might require multiple positions or freezeups. The technique works equally well for a body section; just use a shallower, wider pan.
Whichever pan is used, make sure the razor saw has access to level ice on all sides for a nice, clean cut." - Mark Mullins of Garner, Iowa
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