Stones soon fill with the plastic, even if run slow, it embeds and wraps around the stone. A fluted cutter, if not run too fast, will cut without melting the plastic or filling with the plastic. Even when fluted cutters load up it's easy to remove the build up with an old dull X acto blade. Stones work well with steel and OK with some brass, not so well with aluminum and copper. There are some very hard aircraft aluminum alloys which cut ok with stones as do some beryllium copper alloys. Except for Bakelite stones are not very good on most plastic. Rotary rasps work with common aluminum, copper and plastic though they leave a rough surface that needs finishing with files, sandpaper, wire wheel etc, They are easy to pick clean when they load up. While writing this I recalled something that no one has mentioned that may work well on Mannyrock's task. Remember the Rotozip cutters they look somewhat like a drill bit but are optimized to cut on the sides. mounted in a hand grinder a 1/8" Rotozip bit would work well. I would still encourage some method to fasten the 2 x 2 building down. You will then be able to use both hands to guide the cutter. j
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