Hadn't thought of that before; and it's an excellent point. I had some plastic sticks from something, the sort of which I don't know the material. When I heated it with a torch I immediately began coughing and choking from the fumes it gave off. Not "Smoke" - "FUMES". It didn't take me long to stop messing with that poisonous stuff. Don't remember what the reason for melting them were, but it was most definitely NOT worth the danger of toxic fumes. Maybe that's what stunted my growth.The plastic could be cut with a hot knife, but it may generate toxic fumes in the process.
This used to be a real PITA until I learned how to use 3D design software. Now I can design a box and cutouts anyway I want.Has anyone tried making rectangulr holes in ABD plastic boxes using a hot cutting knife. All the posts I've see use drills and gring tools. Seems the hot knife would be easier.
For using chassis punches on ABS boxes and lucite panels I take two pieces of scrap aluminum or steel sheet larger than the hole I want, which are pre-drilled with the punch bolt hole. Then I drill the bolt hole in the plastic. Then line up the holes and glue them together with cyanoacrylate cement applied inside the area that will be punched out.I have a Greenlee set, but they tend to splinter the box if not exceedingly careful.
You can get Greenlee punches for a lot of different devices, a long while ago I purchased the ones for DB9 terminal socket when I had many to do.We had a real nice Greenlee set at work. Great for doing 1/8 and 1/4 DIN panel cutouts along with the hydraulic pump. Nice stuff but expensive tools.
I didn't see your post before I made mine. I bought mine about 45 years ago in a Radio Shack store. I just ordered one from Amazon when I saw the old RS tool was available.
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by Aaron Carman
by Ikimi .O