Pre-drill round holes in the corners of your square hole. That way, any
cracking will stop at the corners.

Ed wrote:

I need to cut a square hole ( 1" x 1.25" ) in a standard plastic
electrical box cover ... in this case, its the type with one hole for a TV
jack. The new square hole will be to mount a chassis jack for Anderson
Power Pole connections. ( Powerwerx HS-4 ).


Can anyone advise of the best method and tool to do this? I am concerned
about cracking the plastic if I don't do it right.

Ed K7AAT



--
Joe Leikhim K4SAT
"The RFI-EMI-GUY"©

"Treason doth never prosper: what's the reason?
For if it prosper, none dare call it treason."

"Follow The Money" ;-P

Pre-drill round holes in the corners of your square hole. That way,
any cracking will stop at the corners.



That's what I ended up doing to the hard, brittle, faceplate I was
using. Drilled the holes veeeerrrry slowly, with no resulting problems.
Then I used my fine toothed coping saw to cut out the square hole for the
Anderson Powerpole chassis mount jacks. Also put a BNC antenna jack on the
plate. The whole thing will be my HF radio power and antenna connection in
my motorhome. It is now done, looks nice, and should be very functional.

My thanks to all who replied on this subject.

Ed K7AAT