How to make a small precise rectangular hole?

[frank_a]

I need to make a small very precise rectangular hole in my upper cabinet for a small volt meter. My 1st inclination is to use a Dremel tool with cut off wheel very carefully. But seeing I am not in any rush, figured I'd ask you folks how you would do it. Any ideas would be greatly appreciated.

Here's where it's going (near a light for easy wiring):

[Borrego Dave]

A multitool Frank with a half round blade, a very clean cut and easy to control. You will probably have to use a hack saw blade to finish the corners, a few strokes but it is a sweet clean cut, been there done that.

[Seldomseensmith]

Use the middle of the hole for practice regardless of what tool you pick.

[frank_a]

Done. Dremel, heavy duty cut-off wheel, metal ruler clamped to guide cuts.



The volt meter will fit, but tight. I'm not putting it all the way in till I get it wired to the light near it.

[Jack L]

I would have some concerns cutting a hole that large so close to the corners of the two openings shown in your photo. I think you might compromise the structure of that cabinet. That area here you want to remove material would be weakened. Could you surface mount the meter ?

[Jack L]

OOPS ! a few minutes late.

[frank_a]

Originally Posted by Jack L

I would have some concerns cutting a hole that large so close to the corners of the two openings shown in your photo. I think you might compromise the structure of that cabinet. That area here you want to remove material would be weakened. Could you surface mount the meter ?

Um, it's already done! We'll see how it goes. If it becomes a problem, I'll report back.

From my perspective, I would have concerns if I were to leave the hole empty. That is not the case. The volt meter fits tightly in there, and brings structural stability back into play.

Frank

[mary and bob]

I was under the impression that when cutting a hole in fiberglass it was best to have round corners to avoid cracks from starting there. That's what I did in any opening that I cut, like for my new power converter and below cabinet storage access opening. Reinforced those openings with plywood because of their size and the weight of the converter.

[Timber Wolf]

Originally Posted by mary and bob

I was under the impression that when cutting a hole in fiberglass it was best to have round corners to avoid cracks from starting there.

I like to drill holes in the corners before cutting anyway in circumstances such as this. Gives me a defined stopping and starting point if nothing else.

[mary and bob]

Exactly what I did Tim

[steve dunham]

Originally Posted by mary and bob

I was under the impression that when cutting a hole in fiberglass it was best to have round corners to avoid cracks from starting there. That's what I did in any opening that I cut, like for my new power converter and below cabinet storage access opening. Reinforced those openings with plywood because of their size and the weight of the converter.

I reinforced the back side of holes that I cut in the fiberglass (outlets) with 1/4" plywood glued in place with Gorilla glue . Really stiffens and strengthens the area around the hole

[Roy in TO]

A serated or saw tooth blade on the dremel might have been a bit easier.

[frank_a]

Originally Posted by Roy in TO

A serated or saw tooth blade on the dremel might have been a bit easier.

I used a very thin fine toothed Japanese hand saw to make the corner cuts.

Sometimes I wonder if I should even post stuff!

Frank