Options for cutting ABS plastic boxes

[ccfoo242]

I'm using this ABS box for my control panel:
http://www.amazon.com/gp/product/B005T94MQU/?tag=skimlinks_replacement-20

I've seen a variety of tips on cutting plastic boxes using hot blades/knives or Dremel cutting bits.

I only have a few rectangular holes to cut, the rest are circles for the lights and switches.

The heated blades look like they made a clean cut but work so fast I think I could easily make a mistake. I think I'll probably just use a dremel for those.

As for the holes, would forstner bits in a drill press crack the plastic? I thought I would try backing it with wood blocks, covering with tape, then use the forstner bit to drill a clean hole the right size.

Has anyone else tried this? If not forstner what about hole saw bits?

 

[CGish]

As for the holes, would forstner bits in a drill press crack the plastic? I thought I would try backing it with wood blocks, covering with tape, then use the forstner bit to drill a clean hole the right size.

Has anyone else tried this? If not forstner what about hole saw bits?

Both of these ideas will work, but my experience is that the forstner bit will produce a cleaner hole. As long as the piece you are drilling is supported (your wood block idea is good) and your drill speed is not too high for the bit size, you will be just fine. I have had a bit slip - generally as a result of operator stupidity, but never had a piece crack. However, I haven't ever used the specific box you linked to.

Good Luck,
Cody

 

[ccfoo242]

Thanks that's good to hear.

 

[cxp073]

I used a dreme cutting bit (looks like a drill bit) - worked great.

 

[kh54s10]

If you have the Forstner bits, I would use them, backed up with a piece of wood, maybe some masking tape on the area to be cut. Drill slowly and you should get a clean hole.

A Dremel to cut the rectangles. Drill a small hole in each corner to get a rounded turn, this will limit cracks from starting in the corners.

 

[ccfoo242]

Thanks for the tips.

 

[augiedoggy]

A Dremel to cut the rectangles. Drill a small hole in each corner to get a rounded turn, this will limit cracks from starting in the corners.

This is what I Do. It works well for me. only I use one of the vibrating cutting tools with the fine blade one I drill my holes.

 

[BadNewsBrewery]

A jig saw with a finer tooth blade would work pretty well for the square holes, too.

 

[ccfoo242]

I have a decent jig saw, I may have a good blade too. If I use the dremel is this the bit? http://www.amazon.com/dp/B00004UDIB/?tag=skimlinks_replacement-20

 

[BadNewsBrewery]

That'll work fine, just use it at slightly slower speeds so it cuts and doesn't melt the plastic. Be careful - a bit like that will start to wander unless you use a guide. A jigsaw will at least tend to be a little straighter without a guide.

Also, little tip - if you go to smile.amazon.com instead of amazon.com, you can still buy the same stuff at the same price, but Amazon will make a small donation to a charity of your choice. Zero cost to you, but some benefit to the community!

-Kevin

 

[augiedoggy]

That'll work fine, just use it at slightly slower speeds so it cuts and doesn't melt the plastic. Be careful - a bit like that will start to wander unless you use a guide. A jigsaw will at least tend to be a little straighter without a guide.

Also, little tip - if you go to smile.amazon.com instead of amazon.com, you can still buy the same stuff at the same price, but Amazon will make a small donation to a charity of your choice. Zero cost to you, but some benefit to the community!

-Kevin

+ we use smile at amazon to raise money for an animal rescue the girlfriend and I are part of.... I buy stuff through it all the time.

 

[balrog]

The ideal would be to sandwich the plastic, clamped between wood, and drill with Forstner, but setting all that up to index correct location is a royal pain. Just slow the drill press down and it'll work fine. I've used a coping saw with good results too, just to throw yet another possibility into the mix.