Step 3: Cutting the PVC Sheets
Once you have mounted the sheets of paper to the sheets of PVC, clamp them to the saw horses. When starting a cut or cutting tight corners, I find that drilling holes first (using the dremel) is very helpful for producing cleaner results. Always cut the small shapes from inside of the larger ones before cutting the larger shapes.
After cutting all of the parts from the PVC sheets, use different sanding drum bits from the Dremel Sanding/Grinding Kit to refine each part. Clamping a metal ruler to a part helps immensely when shaping straight edges using the Dremel. Next drill holes using the Dremel Work Station, guided by the paper still taped to each PVC part. Finally, peel off the paper and voilà, you have finished parts.