Make:

• Learn about electronics: Relays 101
• How-to Tuesday: USB7 build
• SV Chronometer – a GPS based, interactive master clock
• Record your heatbeat for the neighborhood to see
• Desulfator kit
• Using a DC motor as a servo with PID control

I am a big advocate of good old fashioned hand tools. Put away the Dremel -- for working in plastic, it's more trouble than it's worth. I have seen many projects on the internet that have been butchered with a Dremel that would have been far better if executed with a little patience and skill with hand tools.

A good start is a mixture of different files (different cuts, sizes and profiles), a hack saw and a coping saw.

Using the rectangular switch cut-out as an example:

1. Mark the cut-out with something that will give a crisp, clean line. Use a ruler to mark straight lines.

2. Use a drill to drill out the corners, and shown in the article. Leave some extra meat between the edge of the holes, and your lines. It's easy to file material away. It's impossible to put it back.

3. Use a coping saw, or broken hacksaw blade to cut the straights. Again, stay within the lines.

4. Carefully file the remaining material away.

It takes more time, but the process is more satisfying than using a screaming Dremel with a grabby cutter, and bathing in ABS or polystyrene fumes. You will also be impressed with the results.

Posted by: Collin Cunningham on June 6, 2008 at 10:56 PM

Thank you - that sounds like an excellent alternative.
Somehow I never acquired a coping saw - now I must!

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