The rotary is like a Swiss Army Knife for model railroaders. It can be used for many different tasks, and cutting off nail heads is just one of them. This is when a nail is hammered into a board at an undesirable angle, but can’t be pulled out by pliers without further damaging the wood. Using an attached cutoff wheel, the rotary can remove the protruding nail head for a smooth surface and finished look, despite the remaining nail still within the wood.
Step 1. Eye Protection
Wearing safety glasses or any other eye protection is a must, regardless of how small the job might be. Sparks and debris can fly in any direction.
Step 2: Cutoff Wheel
Cutoff wheels can either come with the rotary tool as part of a kit or sold separately. They are small and fragile. It’s important to hold the tool in a way that keeps it firmly in place without putting excessive pressure on the disk when making the cut.
Step 3: Cutting the Nail Head
Trains.com Director David Popp recommends laying the rotary across a flat surface with the cutoff wheel over the area where the nail head needs to be cut. Dip the tool down so the disk can apply light pressure on the nail. Reposition the rotary at a different angle for a second cut if the first doesn’t make it all the way through.
Step 4: Smooth Things Out
Despite cutting off the nail head, you’ll likely have some protruding nail sticking out of the wood. Use a hammer to gently tap the remnants into the wood and shape any pulled surface fiber back into place.
Members can watch a Trains.com Video on how to cut off nail heads with a rotary tool, coming soon.
