Cutting windows in project enclosures

[Thot]

Sorry for the trivial question:

What is the simplest, cleaniest way to cut windows in a plastic project
enclosure box?
I need to place a DB 25 on one of its walls.

TIA

Luca

 

[Dave]

What is the simplest,
Dremmel Tool

cleaniest way to cut windows in a plastic project
enclosure box?

Not clean but really simple.

Dave

 

[Chris]

Sorry for the trivial question:

What is the simplest, cleaniest way to cut windows in a plastic project
enclosure box?
I need to place a DB 25 on one of its walls.

TIA

Luca

Hi, Luca. The simplest and easiest way is (of course) the most
expensive. Mouser has Deltron rear and front mounting DB-25 D-Sub
connector punches available as their P/N 38DM941 (rear) and 38DM943
(front). These are available for the miracle low price of $247.51 USD
ea., and they're worth every penny if you're cutting a lot of holes.

For a "onesie" or hobbyist application, pick a thermoplastic or easily
machineable plastic enclosure. Using the D-sub connector as a
template, trace the outline of the connector on the plastic. Use a
calipers to get any offset between front and back of the connector,
then trace the real hole with a straightedge. Then use a Dremel tool
(preferred) or a starter drill and a sharp knife to trim out the hole.
After you're done, front-mount the connector to hide any goobs or small
irregularities. ;-)

Good luck
Chris

 

[tlbs]

The absolute "cleanest" way would be to use a cutting die specifically
made for DB25 connectors (available from larger electronic parts
distributors). This is also one of the simplest ways. Unfortunately
it is also one of the most expensive ways.

I have used a "nibbling" tool to cut holes in metal chassis to specific
shapes. The same tool would also work for plasic, so long as the
thickness of the plasic is not greater than the maw-width of the
"nibbler" tool. Even RadioShack sells "nibbler" tools.

 

[Michael Black]

Not clean but really simple.

Dave

That's what bezels are made for. Cut the hole, then put something that
isn't clear around the edges of the clear pastic covering this window (such
as paint), so the choppy cutting can't be seen.

Michael

 

[colin]

Sorry for the trivial question:

What is the simplest, cleaniest way to cut windows in a plastic project
enclosure box?
I need to place a DB 25 on one of its walls.

If its plastic I wonder if you could use a scrap metal DB25 shell and heat
it up so it melts itself a hole through the plastic. it might just work, or
it might go horibly wrong and u end up with a big blob of molten plastic on
the bench ....

Colin =^.^=

 

[Rich Webb]

Sorry for the trivial question:

What is the simplest, cleaniest way to cut windows in a plastic project
enclosure box?
I need to place a DB 25 on one of its walls.

In addition to the other good ideas already posted, here are a some from
the wood shop.

If you don't already have it, look for a project box that has a
removable front panel which sits in recessed grooves between upper and
lower clamshells. Makes life much easier to be able to work on it as a
flat surface.

If you can get hold of a drill press, use a bit just smaller than the ID
of the void to cut a series of slightly overlapping holes down the
centerline of the void area. Gives you less to nibble away with the
Dremel when it's time to cut to the final outline.

This also works if the DB25 hole needs to be on the side of a
rectangular box. Support the innards with scrap wood and drill from the
outside. Requires two people or creative bracing. Do not try to hold it
standing on end with one hand and operate the drill press with the other
hand.

Even better is an ordinary scroll saw. Drill one pilot hole nearly
tangent to the outline and then a single cut with the scroll saw should
be all you need. With a little care (and practice and a bit of deburring
(no pun intended)) this can give excellent results.