Cutting acrylic

[IamDonSharp]

The case I currently have (aspire X-discovery) has a clear acrylic door on the front. My question is, what would be the best tools, and the best way to cut a hole into it so I can plug my usb and front audio cables in without having to keep the door open(I like to charge my ipod and put on headphones, but don't really feel like keeping the door open and in the way). I also need to cut a hole to fit my little car cig lighter(thermaltake x-ray, xmas gift from gf, it's pretty sweet) cause the door won't close with it in.

Tools I have laying around are as followed, electric drill with numerous hole saws(for circular) and a 1 speed rotary tool that I'm not too sure will work cause it might melt the plastic at it's high rpm. Suggestions are more than welcome, or else I wouldn't have posted . Also for anybody that would recomend taking the door off and not using it, I like it and want to keep it.

DonSharp

 

[VballCoach]

how big a hole do you need it to be?

you can use a hole saw. I would suggest taking the door off, taping the whole surface with painters tape..thats front and back. then when using the hole saw you'll need to keep the saw cool when you cut it. don't go too fast and use lots of lubricant. I use a lubricant spray at my work(for aircraft) when I cut any plastics. then you can clean up the cut with by wetsanding starting with 180 then 240 then 400 then 600. keep the painters tape on the whole time. after your done then remove the tape.

 

[Carnage4]

The rotary tool will melt your plastic/acrylic.

I tried a similar project involving cutting holes in acrylic pieces on the front bay covers of my case (home-made fan switch mounts), and normal drill bits (used for wood or metals) will catch the plastic and tear the crud our of your door. Depending on speed, it may cause fractures in the acrylic as well.

You may want to go to a local hardware store and buy a few appropriately sized masonry drill bits (Example). The main difference is that masonry bits will not dig into (EDIT: catch while spinning) your plastic and tear; the same problem exists when trying to drill holes in tile or stone.

My $0.02.