Cutting Slots Into Abs

[PIC]

Hi,

I have an ABS case similar to this one (datasheet):


What is the best way of cutting slots into it?

I was going to use a file, but I remember reading something like plastic clogs it up.

[tekwiz]

Use a Dremel with straight cutting bit to rough out the slot(s), then file the rest. Alternately, a bunch of small holes can be drilled near the periphery of the slot instead of the straight cutter.
Plastic will not clog files unless they are dull or not the right type for the job. Plastic pretty well demands coarser files & single cut will do a smoother job.
Rubbing chalk into the file before use will also retard clogging.
Not also that some clogging always occurs, no matter what material is being filed. A file cleaner or fine wire brush should be kept on hand for cleaning.

Needless to say, an accurate layout is essential to accurate results. This means that the outer edges of the slot should be marked with accurate scribed lines, to provide a reference to file to. Done properly, it's not too difficult to produce openings accurate to ±.002" with this method.
You can lightly clamp the case in a vise, with the layout line exactly even with the jaws & file to the upper jaw surface as an assist in getting the edges perfectly straight.
For maximum accuracy, always work to the same edge of the scribed lines, either the close edge or the far edge, whichever works better for you. In other words, you would file either until you just touch the line, or until it just disappears.
This is necessary because even a narrow scribed line is .010" wide, & this is more than enough to make the difference between a friction fit & a loose sloppy fit.

[PIC]

Thanks tekwiz

[tekwiz]

Anytime. I hope this gives you what you need.