Is there a trick for cutting a square hole in a dash panal?

[polokid69]

Anyone have any suggestions for cutting a hole for a switch in a dash panel ?

[specboy]

Depends... Where are you putting the switch, what kind/size switch is it, what's it for...

oh... and can you use a round switch like this one?

I'll often use a drill bit to cut a small hole and then a fine grade file to work my way out to create corners. Other times I'll use a Dremel with a cutting blade to cut out a square (if it is a bigger hole.) You can drill tiny holes in all four corners and the dremel to cut from corner to corner.

~SB

[polokid69]

It's a small toggle switch and going in the side of the console by the e-brake. I have a dremmel but still learning how to use the diff attachments and which ones I want to buy

[awptickes]

A square drill bit. Duh.

No, seriously, there are a couple ways you can do it. I'd recommend using a nice new xacto knife if it's just plastic. Drill a little hole, then work it bigger using the xacto knife. Easy.

[polokid69]

Originally Posted by awptickes

A square drill bit. Duh.

No, seriously, there are a couple ways you can do it. I'd recommend using a nice new xacto knife if it's just plastic. Drill a little hole, then work it bigger using the xacto knife. Easy.

guess I can try that. Just want to get a clean cut.

[awptickes]

Xacto blades will leave a nice clean cut. Another trick is to hit the spot you're about to drill and cut with a hair dryer for a while, not to burn or melt it, just to get it nice and warm. Once it's warm, say about 95F, drill the holes in the corners. Warm it back up to 95F, then cut between the holes and clean up the edges. After that you'll have a nice clean square with slightly rounded corners. If your switch doesn't fit just let the plastic cool completely, then use a file (nail files work fine, or a bastard file would work too) and grind down the edges until the switch fits.

Hope that helps.

[specboy]

Thought a little bit about this more... I think the easiest solution is to drill a hole using a bit the same diameter as the plug. then cut out the corners with an xacto or dremmel. remember, most switches have a lip that keeps them from being pushed through and also helps cover minor mistakes...

~SB

[Vanishing Point]

Originally Posted by awptickes

Xacto blades will leave a nice clean cut. Another trick is to hit the spot you're about to drill and cut with a hair dryer for a while, not to burn or melt it, just to get it nice and warm. Once it's warm, say about 95F, drill the holes in the corners. Warm it back up to 95F, then cut between the holes and clean up the edges. After that you'll have a nice clean square with slightly rounded corners. If your switch doesn't fit just let the plastic cool completely, then use a file (nail files work fine, or a bastard file would work too) and grind down the edges until the switch fits.

Hope that helps.

I agree, drill four holes in the outer corners of the square and then use your Dremel tool with the smallest cutting wheel to cut out the square. The drilled holes will prevent the plastic from splitting out beyond the cut out.

[wdb]

I'd recommend drilling a hole the diameter of the desired square, then using a flat file rather than an exacto or dremel tool to square up the corners. More control, nice square corners. Use a pencil or similar marker to outline the desired result, then file out to the lines.

[Lyon[Nightroad]]

If you aren't committed to that position I would recomend using the location on the fuse panel cover. You know, those three plastic rectangles to the left of the streering wheel where the vsa switch or illumination swtich would go. You can pop the covers out of the panel and drill into the cover. Thats how I mounted my switch for my lighting relay. I'd recommend that because its only a dollar or two to order a new cover. However the center console will set you back significantly more if you screw up. I should mention that I'm yet to see an automoive swich that mounts through a square hole. All the ones I've used are a circular hole with a bolt to hold it on.




You should get one of these in red. Everyone will 'LOLWTFROFLMAOBBQSAUCE?' when they see it.

[specboy]

My Basooka bass tube had a rectangular rocker switch. Actually almost all rocker switches have a rectangular cutout. Search Rocker Switch on ebay and you'll see. Also rocker switches tend to be a little more flush and seamless (for an add-on) than any other type - unless you buy an OEM switch for something else and "re-purpose" it.

~SB

[henry21r]

i will advice you not to do by your own... .go to garage and pay ...that will be good and safe too.. for you as well as for your car...

[specboy]

Originally Posted by henry21r

i will advice you not to do by your own... .go to garage and pay ...that will be good and safe too.. for you as well as for your car...

He's not rewiring the car, just looking to cut a nice smooth hole in a piece of plastic. This is definitely a DIY project as it should be even easier than replacing a head unit.

~SB

[Aviator902S]

As described in above responses, this is a relatively easy task. One note of caution: Make damn certain that there's nothing behind the panel that you do not want to drill into, ie: components, wire bundles, etc.

If space is limited put several wraps of electrical tape around most of the drill bit's length, leaving only enough of the pointy end exposed to just penetrate the panel and go no farther through than that. Without this tape (or alternatively a proper drill stop) the tendency is for the drill to lunge foward as you push on it and it breaks through the back side, penetrating much farther than you intended.

[kenchan]

if you can remove the panel from the car i would drill holes about 2-3mm inside the rectangular outline and use a large box knife to cut it to the edges.

if you want to use a small saw, you can get a japanese wood worker's saw like this. Precision RC Drilling and Cutting: Japanese Hand Saw, Hinge Slot Cutter, Du-Bro Specialty Bits


im thinking of getting one from garretwade...those are like $50 each