How to cut a rectangular hole in plastic...?

[InSides]

Just as the above states... I am trying to do some experimenting on my DT 990 Pro's and I need to cut a hole in the right cup.

This hole should be with the same dimensions and at the same location as the rectangular hole in the left cup that houses the cable strain relief. I noticed there are some small indentions in the right cup that outline exactly the hole I need - so I am probably going to trace those lines.

The big question though - how to start and what to use? I have never done this before and I would hate to trash a perfectly good pair of headphones. The big issue is that it is a rectangular hole.

Oh, and... I don't have a dremel - nor can I access one in the near future.

 

[thrice]

Well, you could drill a hole smalller than the opening you want and then get a small file and file it into the shape you want.

 

[NiceCans]

Quote:

Originally Posted by thrice Well, you could drill a hole smalller than the opening you want and then get a small file and file it into the shape you want.

files = the poor-man's Dremel

 

[frdchang]

i have a dremel, but i still prefer using a file to make those perfect rectangular cuts.

it helps to mask out the area not being cut so as to protect the surface finish from scratching.

1) drill hole so a dremel can get in.

2) dremel out the course shape

3) file it to a perfect rectangular shape.

works for wood, plastic, metal.

 

[kramer5150]

drill the hole roughly to the same size as the square you want.

us a sharp x-acto knife and carefuly trim away the plastic to make it a rough square.

get a small triangular shaped file and file it smooth. Theyre around $5 at lowes / home depot.

 

[Nordic]

hobby supply shops for model aircraft normaly have little bags with a variety of small files for dirt cheap.

 

[blaken]

I use these

http://www.radioshack.com/product/in...entPage=search

$2 can't beat that.

Or you could go all fancy with these

http://www.radioshack.com/product/in...rt&tab=summary

Hey Nordic could you send me a larger version of your avitar thats halarious.

 

[mb3k]

If the plastic is the "right kind" of plastic, a dremel can actually be a bad tool for the job as it may melt plastic. I'd recommend files for the headphones.

 

[Garbz]

That depends on the dremel speed.