Cutting Plastic?

[TommyG]

The title gets right to it. How do you cut plastic for things like DVIs, buttons, connectors, and such to make them look good? I can normally do my buttons and connectors just fine, but when it comes to cutting things like windows for DVIs I'm not normally looking at straight lines, and the finished product looks unfinished at best.

Not the best picture, but you can tell even at that distance that my window doesn't look very good. I used a razor knife to cut it out, and could probably go a little larger to bring the DVI even with the case.

 

[asdaq]

I would suggest making a hole smaller than you need, make the corners square with needle files, then gradually take some more material off of each side checking the fit as you go.

 

[slimest]

If you need straight lines, use something like a steel ruler to help. It will limit grinding depth. Double side tape can support the ruler.