What tool(s) are best utilized for cutting relatively precise rectangular holes in ABS plastic?
Cutting Tools – How to Cut Smaller Rectangular Holes in ABS Plastic
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My experience says to use the rotary tool, but I have always used metal boxes with plaster rings. I have no experience cutting drywall over plastic boxes. I do have three pointers for cutting with a rotary tool:
- Put as little pressure on the box from the drywall as possible. The more pressure against the drywall, the more likely that you'll get tearout near the edge of the box.
- Leave any NM cable sheathed and set the depth of the cut to the minimum possible to reach the box plus a half an inch (keeping in mind that the drywall will be at an angle to the box).
- Always take a few seconds to visualize your cut. Have a good idea of where your corners are so you can anticipate direction changes. Do a sanity check and make right sure you know which way counterclockwise is. Start out going clockwise, and you'll spend a lot of time repairing drywall.
If you still don't want to use the rotary tool, there is another option. There are tools that attach to plastic electric boxes. You put them on and then position the drywall where it will be installed. Press the drywall against the tool, and it will place small perforations at the outside corners of the box. Connect the dots and cut. The image below is of one of mine, but I haven't had the chance to use it yet.
Grinder is best tool for this job....maybe even you can use the one that you have just make sure you have several plates in order to complete the job. If your grinder isn't enough 115mm one is big enough for sure....When you cut it don't just go straight down like you are cutting a butter but once you cut through wall on one side rotate your beam (or column, whatever that might be) for 90 degrees and repeat this for all 4 sides. But be really careful grinder is really dangerous tool unless you are skillful. It can be heavy and can slip from the thing you are cutting which may lead to injury. Also be extra cautious about the sparks....they can set things on fire, so make sure that anything flammable isn't around.
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Best Answer
If the material is thin (around 1/16th inch give or take) then a hand held nibbler can be good for small square holes. You can drill a round hole to remove some material and then square it up with the nibbler that makes straight cuts. An added bonus is that the tool works when you only have access to one side of the workpiece.
Nibbler Tool
The tip you see moves up and down as you squeeze the handles and it takes a little rectangular nibble out of the material each time.