02-25-2011, 09:54 PM
Actually, the Dremel with a regular cut-off disc is fine for cutting gaps, too: just because it's not perpendicular doesn't mean it won't work. I have several thicknesses of discs (.020", .030" and .040") and use Plastruct ABS plastic of appropriate thickness to fill the gap, using ca to affix it in place. After the cement has cured, simply carve it to shape with your X-Acto knife - the dark grey plastic doesn't even require painting.
Wayne
Wayne