Any tool to make small rectangle holes?

[atikovi]

Need something to make holes in thin plastic for this switch.

Hole size is .515" x .625" Been drilling 4 pilot holes at the corners, then cutting out with a razor blade and finishing with a file. Pretty fiddly job that takes an hour to do. Do maybe 5 times a year. Any better way? Like a panel punch?

 

[LXCam]

They make panel punches in all kinds of sizes, but those can get expensive. I know the couple that I have were 2-3 hundy a piece.

Try here

http://www.panelpunches.com/

You could also make a master gauge out of steel they get a 1/8" rotozip cutter and do I way faster. Just like a router gauge.

Maybe you can do a modification with a existing size. I know I use one of mine for squaring up corners all the time, but it's a real PITA doing so.

http://www.ebay.com/sch/i.html?_nkw=greenlee+square+punch

 

[rice rocket]

I'd probably use a oscillating multi-tool. Should take about a minute.

 

[Zeke]

Make a steel template and drill all around the inside perimeter. It will be fairly easy to cut that out. If you're brave enough, use a spiral cutout tool.

 

[j-guenth]

Make a pattern and draw it where you want it.

Use a series of drilled holes and finish off with a file. I have done many holes this way.

 

[Robby321]

i'd probably use a oscillating multi-tool. Should take about a minute.

yep!

 

[Monte]

multitool or dremel

 

[Hondarancher4435]

Roto zip or dremels work well

 

[MFolks]

If you can find them,Greenlee chassis punches will make square holes.

 

[CJM8515]

A dremel if careful would do it, but if it spins to fast all it will do is melt the plastic. Same with the rotozip. The oscillating tool would work best.

 

[ihateminimumwage]

I'd probably use a oscillating multi-tool. Should take about a minute.

This is the way I'd do it.
Just bought the M12 Oscillating Multi-tool. Always looked at them as a gimmick tool, but boy was I wrong. Love the damn thing. Clean easy cuts in all kinds of materials.

 

[PJNJ]

Dremel with ez lock plastic cutting disc and or spiral bit depending on size of hole.

 

[ttpete]

Adel nibbler. Drill a starting hole and nibble away. Makes square corners.

http://www.adelnibbler.com/

 

[ephotrod]

Drill a hole the approximate size and use a hand file to square it off.

 

[lilredex]

Have seen this nibbler on a Radio Shack card for about $6.. at PAL.

http://www.silentpcreview.com/forums/viewtopic.php?t=39642

Or this other one. Either will do the job.

 

[SantaAna12]

If you can change switch style to a round body, or round beauty ring, then you are gtg with a hole saw or step bit.

 

[FigureItOut]

Hot knife and several practice runs on junkyard trim pieces. The hottest hot knife you can get and move quick.

Sent from my SAMSUNG-SGH-I337Z using Tapatalk

 

[gearhead1]

I've had success with a Dremel and also heating up a utility knife blade with a propane torch and cutting with that.

 

[Dirtydan69]

This is the way I'd do it.
Just bought the M12 Oscillating Multi-tool. Always looked at them as a gimmick tool, but boy was I wrong. Love the damn thing. Clean easy cuts in all kinds of materials.

Totally agree. My first one was a corded Drexel. Burned that one out. I now have the Bosch cordless I use for fine smaller detail work. I have a Milwaukee 18v I use for things I want to be aggressive with. Best tools ever invented.

 

[FigureItOut]

If you can change switch style to a round body, or round beauty ring, then you are gtg with a hole saw or step bit.

I don't know if you're speaking from experience, but in my experience step bits will tear up auto trim pretty bad, often cracking it. My results with them were only slightly better than with twist bits which are nearly certain to kill the piece. Hole saws are okay, but annular cutters give me good consistent clean smooth holes in auto trim for switches and such.

Sent from my SAMSUNG-SGH-I337Z using Tapatalk

 

[zkling]

Can you get to the back side or are you doing these in place? If you can get to the back side a punch or even mortising chisel would be clean and quick, but needs to be backed up. For square holes in sheet metal and plastic I have used a dremel with a cutting wheel and pre drill out the corners, use care and the curvature of the wheel doesn't over cut that much on thin material.

 

[atikovi]

Ordered a nibbler, http://www.skygeek.com/aircraft-tool-supply-64823-hand-nibbler.html Think if I can drill a starter hole, the tool should square it up in no time to fit the switch. Yes I take the whole thing out of the car. Found a video on the tool at