I do a lot of cases in small to medium size quanties.  I use ready made
cases and cut the holes with a milling machine.  I square the corners of
the holes with a file.  On holes that need to have square corners and
fairly accurate dimensions I make metal templates that I pop into the
enclosure to use as a guide for the file.

I have just converted one of my milling machines to a CNC so I can get
faster and more accurate results.  I was planning on offering small run
service to other list members once I have it completely set up.  Contact
me off list if you are interrested.  I, or another machinist, can also
make you a steel punch for an arbor press so you can pop all the holes
in one stroke.  That is a good alternative if you will need other small
runs of the same box in the future.  For not a big investment you can
sit it in the corner of your shop and pop out a box every 10 seconds
whenever you need a few.

Vitaliy Maksimov wrote:

>Hi List,
>
>Does anyone has experience making their own plastic cases.  Something relatively small (2x5 inches), with a couple of openings for the 7-seg display, three or four buttons, and a LED.  And, how difficult is it to modify an existing case - I suppose I could drill the round holes, but what about the square/triangle openings for the display and the buttons?  If the effort isn't worth it, how much should I expect to pay to have 100-200 of those cases made by someone who has the right equipment?
>
>Thank you in advance for your suggestions,
>
>Vitaliy
>
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