Making a square hole

[obonaventure]

OK This is not for my truck but I guess it could be......

I'm taking a brand new computer motherboard from a small case and putting it into an older tower case. The new motherboard has front mountable USB ports and the old case does not have the necessary square hole. So I want to make one.

I need to make a square hole in a thin piece of plastic (the front faceplate on the computer). What do you guys recommend I do to acomplish this?

My thoughts are to make the outline, drill a series of holes just inside the outline, break it out and file until it is perfect (or as close as I can get it).

The thing that needs to go in the hole fits in from behind so any imprefections would be noticable, but not the end of the world as its only a computer.

 

[Tx_Atty]

a dremel would help with that but that is about all I can offer. They have cutting blades so you could draw the line and cut along it rather than drill.

 

[Scarlet_Nape]

A dremel would be the easiest. If not, you might try a larger drill bit (depending on the number of USB ports). You could then "square it out" using some sandpaper.
Or, you might check the local computer store for some very small doors (hinged). Then it won't matter what the hole looks like. You could just close the cover when not in use.

Hope that helps!
John

 

[RoyBoy]

I've used the drill and file method before, probably your best bet unless you are really steady with the dremel, they can get away on you.
A good sharp file will cut the plastic out pretty quick.

 

[pdt1081]

If it's really thin plastic, why not just use a razor knife? As long as you can hold it steady and not let it slip past your corner.

 

[haulin8or]

Square hole, square bit... I would go with a Dremel tool with a cutting wheel, not a cutting bit. Cutting bits can get away from you but the wheels are easier to control.

 

[architect-builder]

How big is the hole? Go to Home Depot or Lowes, buy yourself a small stick of square aluminum square tubing (if they have the right size), cut a small piece off and use it for your jig with a dremel or rotozip. Chances are, you will be able to use the rest of the tubing for some other mod for your truck. They are great for mounting air tanks.

Just a thought.

Barrett

 

[oi8228oi]

100% endorse the Dremel

 

[obonaventure]

Its a done deal. I used the dremel on the long edges and the drill bit on the short edges.

Looks good too! It was a very tight fit in the end because I cut on the inside edge of my outline and filed slightly from there.