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I'm looking to use Rare Earth magnets for connecting chaos marine bodies to arms so I can swap them out. Will I be looking at buying the smallest magnets they have? Will the next size up work well for dreadnoughts and vehicles?

For anyone who does this, I'd have to assume you're using a Dremel tool to cut out the correct sizes. I have a Dremel but have no clue as to what attachment would be right for this.

I'm looking to order my magnets and dremel bits at the same time, so maybe someone has some advice?

I get my magnets at K&J Magnetics online ( http://www.kjmagnetics.com/ ). Really huge selection (though most sizes are in metric). I got the Dremmel Drill bit pack (like 8 small bits) and just got the closest magnet size that fit.
I haven't made weapons options swappable on troopers, but I have done back packs etc. You need small magnets, but you can use one small magnet and a smaller bit of metal if space is a concern.
On vehicles, you can really get away with a lot, basically whatever size fits. For heavy peices, like metal dreadnought arms, you will want to have two magnet points in the arm to keep it from flopping, unless you don't mind it hanging down. You can also solve that by having a pin hole and a magnet, but two magnets is probably easier.

I use the 1/8" for most things vehicle (storm bolters, smoke launchers etc.) with the exception of my dread bitz, where I use a 1/3". Really though, I sort of go with what's on clearance and get a mess. Most round disk sizes can be made to work.

One more thing, make certain you get ones with the proper magnetization. On disks that is "axially", in other words one flat side is N, one is S. You can get nearly any type there, so be careful you don't get some funky one.

You'd probably just want to use a standard drill bit that matches the diameter of the magnet. That's what I've done in the past.

I've found that for magnets, a standard drill bit just doesn't do the trick, since you're usually looking for a fairly wide and very shallow depression.

What you want is something like an engraver or a router bit with a flat end- it should have a circular cross-section, flat end, with or without a little sharp point in the middle. The flat end should have little sharp cutting ridges radiating from the center- and probably up along the sides too. I bought one a month ago, and it's been more help than I ever thought one little metal doodad could be!

And yeah, K&J Magnets is a great place to go. American Science and Surplus is really cool too, but their selection's not as broad, and varies with time.

Speaking as someone who's magnetized anything from Tyranid MC's to SM Predators to even my SM sergeants, yes a trooper can be done. After doing a few troopers it really can be a pain. Magnetizing the tanks and MC's is sooooo worth it though and people at the FLGS's I frequent always get a kick out of it, especially my Fex's. Definitely get the smallest magnets you can..it'll cover 90% of the things you're doing. A slightly larger size will cover the other 10%

The router style bit is a good idea. I would also suggest picking up a number of other drill style bits as well for your dremel. Once you get started doing this you'll find that your dremel is probably your best friend for modelling work next to your xacto knife. From drilling out gun barrels to creating magnet holes to filing/sanding down areas, I love my dremel.

Knife, dremel, pin vice, razor saw. What else does a guy need in this world?

Make sure you have all the polarity correct. Correcting this after the fact is a pain I don't wish on you.

I use the large drill bit that came with my Dremel and it works fine for the smallest size round RE Magnet. I usually glue one side, let it dry and then use that to insert the magnet into the other side to ensure the polarity is correct.

Ozymandias, King of Kings

I was about to order off of this site:
http://www.widgetsupply.com/page/WS/CTGY/dremel-engraving
Which of these engravers should I get?
I'm also about to buy this set:
http://www.widgetsupply.com/page/WS/PROD/dremel-bit-set/SCH2-100
Does it look like what I need is in there?

I'm wanting to magnetize marine arms and dreadnought arms. If I ordered two sets of magnets, which ones should i get on this site?:
http://www.kjmagnetics.com/products.asp?cat=10
I was thinking the D201 and D301. The D101 seems too small to be able to hold anything. Am i wrong in this?

Thanks guys, the advice is really appreciated.

I use these:
http://www.rare-earth-magnets.com/detail-ID-121.html

They fit perfectly in a Marine's arm.

Ozymandias, King of Kings