Before we got an xy table with a router, I cut ragged holes with the 
dremel/drill press and used an overlay with a window to "hide" my 
handywork.  I usually needed an overlay or keypad of some sort so the 
cost of the overlay window wasn't a big adder, but a custom overlay may 
be about as much as a commercial service.  Have you considered melting 
it with a one piece metal frame that's the right size for the hole?  
Would take a lot of experimenting to get the technique right, but it 
might work.

Tony


Larry Bradley wrote:
> I'm trying to find a way to cut neat rectangular holes in small plastic box 
> lids for mounting LCD displays for hobby work.
>
> In the past I've drilled a series of small holes, then used a coping saw to 
> cut out the piece. Then file the edges smooth. This is not very neat - the 
> edges are never straight lines. 
>
> When I do something like this in woodworking, I use my router to make the 
> rectangular hole, then clean up the corners. But a router on a small (e.g. 
> 4"x6" box) piece of plastic isn't easy.
>
> I do have a Dremel tool, but I don't have the router attachment for it - that 
> may be an option, since it is a lot smaller.
>
> What do others out there do? Using a commercial service for a one-of box is 
> probably rather expensive.
>
> Any ideas?
>
> Thanks
>
> Larry
>
>   
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