Thankyou for the warning however I am quite aware of the dust of death, I own several full-face gas masks so nothing to worry aboutIf you have a steady hand, you can use a Dremel tool. However, be very careful to use a mask so that you don't breathe in the fiberglas powder.
I like the Sgt's idea - never thought of that.I use a paper cutter, like this one:
Ditto. I usually use an X-acto knife with a straight-edge like a metal ruler. 2-3 scores on each side and snap! Then a little filing.I typically use a razor knife (box-cutter) to score it (on both sides) and then just snap it. Then I file the edge.
While I originally posted that technique, I have to thank someonesdad for pointing this out. It is not for a noobie! Regarding the radial arm saw (I would not use a table saw), you don't have to cut the board through; almost through will let you snap it easily and is safer.you have to have used a chop saw a lot and know how to properly support the piece to be cut; otherwise, the piece can be jerked out of your hand in a flash.
I used to like nibblers, but then I had some experience in a machine shop and it spoiled me for life. The main thing I don't like about nibblers is the tool marks on either side of the square holes.I use a handheld nibbler. It can cut straight lines and also shapes quite quickly and works on front panels too. Works on phenolic or fibreglass PCBs. Or to make square holes.