How do you cut those rectangle holes for the slide switches (spst, dpdt)

[jimmybjj]

...as stated in the title. I can't think of a clean way to accomplish this. Thanks for any help.

[amptramp]

If you are working with sheet aluminum, a nibbler will work.  If you are working with cast aluminum or sheet steel, drill a hole and then use square or triangular files to open the hole out to the shape you want.  Files will clean upany uneven surface left by a nibbler as well.

[mattthegamer463]

If you have access to some eccentric machines, a laser cutter or a punch and die set can make nice rectangles.

For us normal folks, drill a hole with a diameter smaller than the finished rectangle width, and file it to shape.

[Paul Marossy]

I draw the outline of the rectangular hole with an extra extra fine point Sharpie marker. Then I drill a series of small holes, in two rows. Next I use wire cutters to nibble/cut away what is left. Then I finish it up with various small files.

It sounds like a lot of work, but I don't think that I spend more than ten minutes on it.

[G. Hoffman]

Use a mini-toggle instead.   


Gabriel

[jimmybjj]

Use a mini-toggle instead.   


Gabriel

But they don't sound the same 

I draw the outline of the rectangular hole with an extra extra fine point Sharpie marker. Then I drill a series of small holes, in two rows. Next I use wire cutters to nibble/cut away what is left. Then I finish it up with various small files.

It sounds like a lot of work, but I don't think that I spend more than ten minutes on it.

Is this the type of nibbler you guys use?
http://www.homedepot.com/h_d1/N-5yc1vZ1xg4/R-100647884/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053

[earthtonesaudio]

I typically just drill a couple holes and file.  It really REALLY helps to have a nice clean sharp file.

Oh, and I've only attempted this on cast aluminum.

[petemoore]

  The method Paul described...
Or go with a large circle-hole, and put a square patch of substrate that's easier to cut neat square lines into, over it...four screws for the plate.

[salocin]

Depending on the size of the hole required, a dremel can be helpful sometimes. I still end up using a file to clean up though.