Cutting tufnol with hand tools?

[stinkwheel]

Need to make a custom inlet manifold spacer out of 5mm tufnol sheet and I've never worked with the stuff before. Lots of info out there on machining it, not so much on hand tools. I have hole saws I can make the holes with but what best to cut the profile with?

Coping saw? Tile cutter saw? Stanley knife? I assume it will sand down nicely with some zinc oxide paper for final shaping?
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Islander]

It should cut easily with a coping saw/jigsaw/bandsaw and it'll drill and sand no bother. It might be a good idea to wear a mask - from memory the fumes are awful!

[Nobby the Bastard]

What sort of strength is the material?

You can get tile cutting saws that are shaped similarly to a junior hacksaw but have a round cutter rather than a straight blade, making it easier to cut unusual shapes.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[virus]

Coping saw / band saw seemed to work fine when I last used Tufnol, wear a mask though its nasty stuff.
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stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[stinkwheel]

[Nobby the Bastard]

Tiles are tough but brittle, thats why I suggested one of them.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[WD Forte]

[Pete.]

Tufnol is very easy to saw but you're not cutting it with a knife. Hacksaw, coping saw, jig saw hell you could cut it with a mini grinder nd thin disc but only do that outside. File/sand to suit.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[kramdra]

Holesaw followed by die grinder,

or wood router. You could get one of the many laser'ists to cut out a plastic template and use a bearing bit to follow.