Cutting rectangles in plastic, but small ones!

**colin** · 05-04-2009, 05:56 PM

With a cutting disk? Too big. The buttons are quite small.

**mayhembdm666** · 05-04-2009, 07:02 PM

The Dremel tool does do the job, But you need to use other parts apart from the cutting disk. It does have a few attachments like the sharpening/filing bits.

With a little practice, The engraver tip should do just fine for something like the usb logo.
As for the holes, Drill the center/pilot holes and then use what ever you feel best with after that.

**95seriesbmw** · 05-04-2009, 10:24 PM

cut/drill a hole that is obviously too big. tape up the button. hot glue it in the position that you want it in. take body filler and fill the gaps completely. as the filler sets, pull the button back out to release the grip from the body filler. The filler shud be rubber like to touch at this point, but not wet or capable of lossing its shape. then once the filler has cured you simply block sand down to the original piece, paint and reassemble with the tape removed from button.

the way i typed this may make this sound easy and it really it is, but doing it for the first time will be an experience and may not turn out the way you want. if you are experianced with body filler it should be much easier.

this method should work for you and still be pretty cheap to do.

I suggest practice first, then do the real piece when you get it figured out.

**ExpyCarPuter** · 05-04-2009, 10:48 PM

I think the Dremel idea may work maybe using one of those cone sanding bits, thats what I like to use when the plastic is not too thick or rough. Most likely would melt the plastic and give you nice smooth edges rather than burring it with an x-acto knife. My opinion.

**colin** · 05-04-2009, 10:55 PM

Yeah I thought of that, that's my last resort if I mess up. Guess we'll see what happens right.

**jpinkerton** · 05-04-2009, 11:29 PM

Don't forget pics!

**turaboy** · 07-05-2009, 12:39 PM

I've never used one, but these look handy...
http://www.micromark.com/ELECTRO-FIL...HINE,7979.html

**rdholtz** · 07-06-2009, 08:14 AM

Or get these small hand files for $3.99 and shipping.

**colin** · 07-07-2009, 11:58 AM

Thats basically the set I got for like 6 bucks (CAD) at Canadian Tire.

**trader007** · 07-07-2009, 06:55 PM

the dremel is what you want, just use the universal spiral cutting bit made famous by rotozip. just go slow, because those bits love to walk on you.. but it will work perfectly if you have the steady hands for it.