Harbor Freight sells a 5-in-1 Hobby Tool. It is basically a wood-burning pencil with accessory tips, one being an X-Acto knife. I used up a couple of similar tools when building plastic models as a kid and was very glad to see this being made again. One of the best tools for working with plastics. This would be a slow process, but you can get good results. The heat along the knife face varies, so you only want to push it in enough to cut, but not so much as to melt the plastic too much, because it will no longer be a straight cut and will leave excess material at the edge. Very light pressure on the tool and patience are what gets it done.
Never attempted anything like this but I would at least try to put some tape of some sort on the area I was cutting/drilling, might help, hope ya got plenty of lenses. Is there a chemical that will soften it up some? acetone or something...
Copeing saw...Fine tooth saw blades. Drill a hole to start the saw in and slowly cut out your desired hole...Workes every time on hard plastics like a inst cluster lense.
a high speed dremmel with a cutting wheel would do the job. those things will cut through anything harbor freight sells them in a kit for like $10 if I remember right otherwise dremmels are sold pretty much everywhere
Good luck with the roto-zip. It'll probably tear it up pretty good. I think a hole saw at slow speed so it doesn't melt the plastic would be your best bet. Why are you cutting the hole?
I'm with Joe Dirt and Mavman on this one. I've used just about every other method by now and they all melt the plastic to one degree or another due to heat build up. Biggest issue to watch out for is spider cracking from too much pressure and/or chatter related to low tooth count of the cutting tool. Usually best to use foam lined vice/s or any other method(I like wood clamps and tables myself) you can think of to keep the thing solidly planted during the cut too. Just avoid arguments and caffiene before hand.. or invite the most patient and steady handed friend you know and make sure he know's that the beer doesn't start flowing until after the job is successfully completed. Maybe just leave that last detail out until after they show up though.
Rotozip...worked like a champ. I chucked the Rotozip up in my vice and free handed the cut. no burn, just took a half round file and dressed up the cut. double taped both sides, marked the hole and went to cutting... thinking about doing another one to see if it was really that easy... thanks for the suggestions...:Handshake
