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Re: [Shop-talk] Cutting holes in small project box

To: shop-talk@autox.team.net
Subject: Re: [Shop-talk] Cutting holes in small project box
From: "Lee Daniels" <lee@automate-it.com>
Date: Tue, 15 Sep 2020 14:09:56 -0500
Delivered-to: mharc@autox.team.net
Delivered-to: shop-talk@autox.team.net
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This is a great list. The suggestions for cutting round and square holes were
spot-on. I ended up getting a decent step-drill (Unibit) set from Amazon, and
in my small drill press at low speed it made beautiful holes in my plastic
box. The square holes didn't take long at all; the plastic was pretty soft and
a quick cut plus squaring up with a small file made for easy work.

THANK YOU for all the helpful replies.
 Lee

On Wed, September 9, 2020 21:33, Brian Kemp wrote:
> Lee,
>
>
> For the round holes, I'd use a sharp drill bit at medium speed and go
> slow.  For the cleanest hole, start with a small one about 1/8" and move up in
> small steps until you get the size you want.  If you have a stepped drill bit
> like a unibit, it should work great.  One with smaller steps will give the
> cleanest opening.  Here is a sample:
>
> https://www.harborfreight.com/2-piece-titanium-nitride-coated-high-speed-stee
> l-step-drills-96275.html or with Coupon 18288307 it drops to $13.99
> https://www.harborfreight.com/2-piece-titanium-nitride-coated-high-speed-stee
> l-step-drills-96275.html?ccdenc=eyJjb2RlIjoiMTgyODgzMDciLCJza3UiOiI5NjI3NSIsI
> mlzIjoiMTMuOTkiLCJwcm9kdWN0X2lk%0D%0AIjoiMzQ0NiJ9%0D%0A&cid=newgetcpns090120
>
> For the rectangle hole, if in metal, use a nibbler like
> https://www.amazon.com/RadioShack-RadioShack%C2%AE-HT-204-Nibbling-Tool/dp/B00
> 7Z7PY48/
> Drill a round hole first then trim it to size.  I have not tried the
> nibbler on plastic.  I'd expect it to crack.
>
> I've also used a small cutoff wheel in a Dremel at slow speed.  It will
> cut/melt plastic, so go a little small then clean it up with a file.  Drill
> small corner holes for the neatest opening.
>
> Depending on the wire holes and if things are moving around, you may
> want to look at a strain relief grommet.  Another option is to use some ring
> connectors for the incoming wires and screw them to the standoff mounts inside
> the box then run a connecting wire to the next step so there is no strain on
> the switch or other components.
>
> Good luck,
>
>
> Brian
>
>
> On 9/9/2020 12:51 PM, Lee Daniels wrote:
>
>> I need to cut a couple of holes in a rather small electronic project box
>> (This
>> one: https://amz.run/3YjE ) - but I'm not sure how to make nice "pretty"
>> holes in this. It has both a plastic and metal covers, either one works for
>> me, but I'll have wires through the plastic side. How does one cut a nice
>> hole in a box like this? Ideally I'll have round holes for wiring and at
>> least one small rectangle for a switch. See photo. Any suggestions
>> appreciated! - Lee
>>
>>
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