How to cut a precice square hole

[voipio]

Mark out the hole outline with a scribing tool, then pilot hole and fretsaw. Should be easy enough in plastics. Choose blade pitch which allows at least three saw teeth in contact with the material being cut. Clean up with a file to the marked out lines.

 

[KemppiFrog]

Router + jig must be the way for low cost/small numbers. Then carefully square the corners. Use a nice sharp 6mm TCT cutter (or even 4mm). I have done a lot of Perspex this way, and have just made a little router table for my artist client to do small runs of Perspex bits for her lights. Fences and stops to keep it easy and accurate.
KF

 

[cazl1994]

buy a fein multi master about £150 quid for the machine and blades are about £7 each and it can be used as a detail sander very handy machine

 

[Dev]

There could also be a problem with a router, the plastic may melt due to friction from the high cutting speed ?

If you're using gee wiz boxes this will almost certainly be the case. I dremmeled out a hole in one today and that was enough to melt it.

 

[Polished]

Is it something like this you are cutting or is the face plate a harder plastic ?

 

[ilovemygt35r]

hi polished
yes its very much like that box, im using

i did think of the multi master/ but im sure a router in a jig would be more repeatable and a better finish in term of a nice edge and once the jig is set.

 

[Seano]

Use one of these.....http://www.rotozipuk.co.uk/?gclid=CJ252LCqkbICFYcNfAodqCoAzQ I use them for cutting all sorts of hole shapes in sheet steel, search rotozip on eBay.

 

[slimjim]

just get it laser cut, it's not that much, this guy on retrorides will probably be able to do it!

http://retrorides.proboards.com/index.cgi?board=othrmod&action=display&thread=133506

 

[Polished]

Something like this perhaps ?

hi polished
yes its very much like that box, im using

i did think of the multi master/ but im sure a router in a jig would be more repeatable and a better finish in term of a nice edge and once the jig is set.

Lots of good ideas coming through here to help.
I think something like this could be made up quickly and cheaply especially if you plan on doing alot of them. Once the edges of the box section are sharp that's a fairly flexible plastic and should give you clean cuts each time. Sorry about the drawing but it's just to give you an idea , some sort of lever operated press, wooden block underneath. Forgot to add, if you make some angle brackets to screw onto the base timber to locate the box/lid will make sure you are cutting same each time. A 2ft-3 Ft lever should give you more than enough downforce to cut cleanly, rough guess would allow you to do 50-100 in an hour with the added benefit of strengthening your beer arm

 

[wheresmejumper]

if it is the softer material then what i meant could be used in conjunction with a press
http://www.ffx.co.uk/tools/product/3380000030070%20freud%20fr-hp100b%20repacement%20blades%20for%20hinge%20pro%20100mm%204in

 

[howardm]

http://www.snotr.com/video/8051/Machine_drills_square_holes_in_metal