How do you cut a rectangular hole for a rocker switch ?

[RichardAllen]

Is there an easy way to cut a rectangular hole 19mm x 13mm for a rocker switch in, say 1mm aluminium ?

Last time, I marked, drilled and filed and it took quite a time to get a good fit. I did not think of using an old chisel.

Any better ideas ?

All help gratefully received.

Regards

Richard

PS THis http://ae.rsdelivers.com/product/m10-rectangular-hole-cutter-193x131mm/0600155.aspx is what I have in mind, just cheaper.

[landmannnn]

I use a narrow jig saw blade and then tidy up with a dremel.

I have got a hand nibbler but as with a chisel I always distort the metal.

[Off Road Toad]

a Dremmel style multi tool is superb, thats what we use for fitting switches to customers cars.

Steve

[tychoS]

Is there an easy way to cut a rectangular hole 19mm x 13mm for a rocker switch in, say 1mm aluminium ?

Last time, I marked, drilled and filed and it took quite a time to get a good fit. I did not think of using an old chisel.

Any better ideas ?

All help gratefully received.

Regards

Richard

PS THis http://ae.rsdelivers.com/product/m10-rectangular-hole-cutter-193x131mm/0600155.aspx is what I have in mind, just cheaper.

You use a drill made for drilling square holes of course ,-)

http://bbs.homeshopmachinist.net/showthread.php?t=92&page=4

The Math behind the drill, the "Reuleaux triangle"

http://en.wikipedia.org/wiki/Reuleaux_triangle

As for a quick, dirty and cheap approach for drilling one or a few holes in thin aluminium that does not have to be super perfect, I use ordinary round drills and small files.

[PS_Bond]

I use a jeweller's piercing saw for obnoxious shaped (i.e. anything not round) cutouts these days.

[FridgeFreezer]

I use a square drill bit

[combivan]

I'd drill a hole and use a Square Sheet Metal Punch