I use a milling machine when I can.  I have one project that uses a small
square hole that needs sharp corners.  I made a template out of 1/8: aluminum
that fits into the inner recess of the enclosure.  I press it in, drill a 3/8"
hole in the center of the square hole, cut to the aluminum template with a
nibbler(available at Radio Shack for about $10.00), and do a little finish
work with a needle file if needed.

Bill Pierce wrote:

> I just wanted to say first that this is a great list. Everything is
> informative or interesting. Anyway on to my question.
>
> I have a product that goes into a Serpac box. I have a few round holes for
> switches that are easy to drill. I also have two rectangular openings for
> the 9V power supply and for a terminal block..
>
> I am cutting the openings with a Dremel tool now but it doesn't look real
> good and I can't seem to get any accuracy. What is everyone else doing to
> make openings in off the shelf enclosures.
>
> Thanks for any advice
>
> Bill
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