Cutting Enclosures: Rectangular Opening Tool?

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SUMMARY

To cut a rectangular opening for an LED display in a metal enclosure, users recommend using a Dremel tool with a thin cutting disk for precise cuts. Nibblers are also suggested for larger openings, although they can be tedious and require additional filing for a smooth finish. For larger holes, starting with a drill to create a pilot hole and then using a fine-toothed jigsaw blade is an effective method. These techniques ensure clean cuts and minimize the need for extensive post-cutting work.

PREREQUISITES
  • Understanding of Dremel tools and their accessories
  • Familiarity with nibblers for metal cutting
  • Knowledge of jigsaw operation and blade types
  • Basic metalworking skills, including drilling and filing
NEXT STEPS
  • Research Dremel cutting disks and their applications for metal
  • Learn about different types of nibblers and their use cases
  • Explore jigsaw blade options for cutting metal enclosures
  • Study techniques for smoothing metal edges after cutting
USEFUL FOR

This discussion is beneficial for DIY enthusiasts, metal fabricators, and anyone involved in modifying enclosures for electronic displays.

david90
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I have this box and I need to cut a rectangular opening to expose my led display. My question is there a tool to make a clean cut of the rectangular shape opening? I tried using a rotary but it is not a very smooth cut. Is there a way to do it using everyday tools?
 
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I am not sure what a rotary is? I will assume it is an metal box.

You give no idea of the size of the hole, that can make a lot of difference. I have used nibblers to do this sort of job. IF the hole is large they can be pretty tedious. Also it requires a lot of file work to smooth it out.

A thin cutting disk on a dremal like tool (is this your rotary?) can do a very nice job if you have patience.

For larger holes, dill a start hole then use a fine toothed blade in a jig saw.
 

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