I Needs A Nibbler!

[M Fowler]

The odd shaped IEC only needs a rectangle opening.

No need to cut the angles at all.

The IEC plug covers the rectangle opening completely.

Mark

[Gaz]

I was lucky enough to find an NOS Greenlee rectangular punch on Ebay. It was almost the right size, and I had to file a little to open it up. Unfortunatey, it got dull, and I hope to get it sharpened. it doesn't use a ball bearing, so it took a lot of work to get it through. Nonetheless, there was no mess or guess, and the hole looked really pro.

Now my big problem has been making a matching a rectangular hole in an 1/8" plexiglass faceplate! I've done a few, but man is that difficult. good thing plexiglass is cheap!

[Bill Moore]

I have a Snap On air nibbler, that I've worn out a couple of punches, and dies on. I used to have to install a lot of accessories in the vehicles back when I worked for the power company. I also used it to help build the panels used in the substations. Once you've spent a little time with one, you can really do very close cuts, using only your layout lines.
As for clean up, (with ferrus metals), a few magnets on the back side of the work, can catch most of the half moons.

[Structo]

I was lucky enough to find an NOS Greenlee rectangular punch on Ebay. It was almost the right size, and I had to file a little to open it up. Unfortunatey, it got dull, and I hope to get it sharpened. it doesn't use a ball bearing, so it took a lot of work to get it through. Nonetheless, there was no mess or guess, and the hole looked really pro.

Now my big problem has been making a matching a rectangular hole in an 1/8" plexiglass faceplate! I've done a few, but man is that difficult. good thing plexiglass is cheap!

Gaz when I have made holes is Lexan or Plexiglas I drilled holes in the corners of the opening I am making.
This helps prevent the material from cracking as you work it.

I usually err on the cautious side but have used my Dremel tool with a fine grit cut off wheel for this before.
Or a fine toothed jig saw blade and cut holding it in my hand or vice grips.
Depending on how long the cuts are.

Anyway, I can think of other things more fun.