[Shop-talk] Making a hole

[Brian Kemp]

John - I've used several methods to make cutouts in boxes.  One is the nibbling tool already mentioned.  I have

http://www.radioshack.com/product/index.jsp?productId=12345949 (or similar from about 1990) and it works well for some plastic boxes and metal faceplates.  Test it on one of your broken boxes.  

You can also use a soldering iron to melt a hole.  The leftover plastic snapped off then I used a file to smooth it.  You will need to re-tin the tip to actually solder again if you don't have an old tip.  Do this with good ventilation as it will stink.

Depending on what you are doing, you can also look for a box with a metal plate at the end or even an all metal box like

http://www.radioshack.com/product/index.jsp?productId=2062217

I will also second the post about predrilling the corners.  To make it easier, go to your shop and put a 2x2 or similar in your vice and use it to support the box.  That way, you have the back of the box supported as you drill.

A final thought is to put the connector flange on the outside of the box, so you can't see that the hole is uneven.

Brian - with fond memories of when I had time for fun projects


-----Original Message-----
>From: "John T. Blair" <jblair1948 at cox.net>
>Sent: Jun 20, 2012 2:20 PM
>To: shop-talk at autox.team.net
>Subject: [Shop-talk] Making a hole
>
>I'm working on a project and using a 6"x4"x2"  "plastic" 
>project/experimenters box from Radio Shack.  I'm trying to install 
>some mini DB9 connectors in the ends of the box.
>
><shop talk content>
>I go down into my SHOP, and clamp the box in the vise.
><end shop talk content>
>
>After I scribe when the connector should go I've tried 2 methods for 
>making the hole:
>
>1. The first was to drill a hole to insert a saw into,  and then use 
>a coping saw to cut it the hole.  This was very time consuming and 
>tough on the box.  In fact I broke several.
>
>2. The current method is to use a circular saw blade on my dremil 
>tool, similar to:
>http://www.sears.com/gyros-82-10715-saw-blade-w-mandrel-set-fine/p-00931176000P?prdNo=11&blockNo=36&blockType=G36
>
>     Once the hole is rough cut, I use a triangular file to clean it 
>up and size the hole so the DB9 connector fits.
>
>I was wondering if anyone had a better idea of how to do this?
>
>John
>
>John T. Blair  WA4OHZ     email:  jblair1948 at cox.net
>Va. Beach, Va                  Phone:  (757) 495-8229
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