Cutting Enclosures: Rectangular Opening Tool?

[david90]

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?

 

[Integral]

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.