My wife bought me a raw carbon fiber sheet (A4 size) in Japan last
year and it's been sitting on my work bench foreever... i want to
make a small switch plate trim for my car (G35C door handle area).

how the heck do you cut CF sheets? knives would dull, obviously
scissors the same... do i use a saw or something even on like a
1.5mm thick sheet and sand it down? im not too good on dremel
tools as i want to get a nice clean line.

any suggestions?

thanks.

 

reciprocating saw

treat it like fiberglass

 

yeh, i guess i can use a coping saw with small pitch blades...

and finish off with a file. anything that will reciprocate too fast or
use large blades will crack this sheet. it is pretty brittle.

 

exacto knife?
score and break?

 

saw it, you can splinter things up by scoring and breaking

 

For CF that thin you can use a jig saw or even better a band saw with a very fine blade, like a metal blade. It can then be sanded with any sandpaper. Just be careful of any splinters and sharp edges.

 

It cuts like any other fiberglass. Be careful of the dust. Wear a respirator or at least a dustmask.
You can use masking tape on the surface, mark the tape where you want to cut; cut, sand, file to fit. Tape also helps to protect the surface you don't want marred.

 

I've never cut CF, but that tape thing mentioned above works great on fiberglass... And masking tape can be drawn on with a pencil, assuring a really clean line. I've used a band saw with a fine blade and it worked great, but really do listen re: dust- that stuff's killer.