Best way of cutting out screen hole for DNA40 (big version)

[foliagegreen]

So I'm almost ready to attempt my first build (waiting on battery sled). I just wanted to know what you guys think the best way would be to make the cutout for the DNA40 screen. I have the newer big screen version. I've seen some pics where people drilled three holes then filed the rest out. Was just wondering if that would be the best route or if anyone else has any other ideas I'd like to know how you guys did it or if you guys could point me in the right direction. Thanks!

 

[drmarble]

A milling machine would be ideal. Without that I would recommend a file. Taking the metal out slowly by hand allows you to get a precise rectangular window. I think that using a dremel to cut the window would be risky. It would be too easy to cut a bit too deep somewhere. Files work great on straight lines and right angles.
I am sure someone else will chime in with good advice and techniques to do it with power tools. I'm looking forward to reading that because it would be much faster.
Another trick is to use a 3d printed bezel. Your edges can be sloppy and everything will still look great.

 

[foliagegreen]

Thanks for the tips. I was definitely thinking I might cut too deep with a dremel. I'm trying to make using 3d printed bezels a last option only cuz I don't think I could wait for them lol. Worst comes to worst, I'll prolly hand file it.

 

[BlueridgeDog]

If you have a machine shop near you, then go over and have them mill it. If not, I have found that a center punch/drill to get a nice hole at each corner, then a cutting wheel on a dremel leaving a 1/16 space from your desired final line is great. After the bulk is cut, you then file the 1/16 off. Don't try and cut the final with the dremel.