SIMCO Disclosures

We discuss all things to do with plastic enclsoures and thier applications in the electronics industry.

How To Cut A Square Hole In Enclosures

November 29th, 2014

The trend of DIY is increasing these days; people are more interested in getting things done on their own rather than paying for it. Many people do their craft work like making cabinets, a shelf for their home or installing the LCD themselves. For all these things you need to be well-knowledge about how different machines work and what purpose do they serve.


If you need to make or cut a square hole in enclosures, whether it’s metal, wood or aluminum you can easily make a square holes within a few minutes, keeping in mind that you the right tools with you. Here we have certain methods from which you can cut square holes in enclosures. So if you have these tools at home then all you need to do is get to your work bench.

First Method

This method is very easy, as you can make square holes in wood by using an ordinary chisel. Square holes are usually made as an alternative of tenon joints or the custom mortise, so if you want to make a project or turn an old fashioned wood furniture into something new and creative you can  easily do it by using this method.

To cut a square properly in straight alignment, you need a drill press to drill the pilot hole after that you can carve the sides of the square with a chisel from hands. First you need to start by cutting a perfect square of ¾ by ¾ inches through a part of poplar.

Things You’ll Require

  • Drill press
  • ¾ inch brad tipped drill bit
  • Poplar board, 4-by-12-by-3/4 inches
  • 3/4-inch chisel
  • Tri-square
  • Mallet


  1. First insert the ¾ inches brad tripped drill bit into the drill press, then place the poplar beneath the bit and switch the drill press on and then drill through the poplar.
  2. Next you need to place the tri-square and then on one side of the hole, you need to draw perfect square lines with the help of tri-square.
  3. Once the lines are drawn you need to place the chisel on top of them, align it with the lines and then tap at the end of the chisel with a mallet to make a line, follow this pattern on the all four sides.
  4. Now you have to put the chisel on any one line and tap hard on it so that its presses down through the hole, as it penetrates the hole its cutting the sides of square hole, you can follow this on all the other sides as well.
  5. Once your hole is made you can then trim and shave it with the chisel to make it smooth and clean.

Second Method

This second method is also very simple through which you can easily make square holes. Usually people like to do small project work or fixing or attaching some equipment at home themselves. Mostly people face difficulty in making square holes, but here is an easy way to make square holes simply by using a sabre-saw and drill bit.

Things You’ll Require

  • Sabre saw
  • 1/2-inch drill bit
  • Drill
  • Sandpaper


1. First, you need to draw the square on the wood using a pencil and ruler be certain that you draw the square in proper alignment and connect the corners properly.


2. Next, you need to use your ½ inches drill bit to yield a pilot hole, remember you need to drill on one of the square corners and don’t drill on the line instead drill inside the line for a proper square.

3. Now you need the sabre saw, insert it in the hole you just yielded, switch on the saw and angle the blade towards the line which you draw for the perfect square. Keep the saw on the line and follow it on all four sides till you get a perfect square.


4. Now you will need you the sandpaper, to smooth the edges of the square, just remember this that you have to be very careful in sanding the edges so that they don’t turn round.

Wood and metal enclosures have always been in use, whether its home or for office buildings. The purpose of wood and metal enclosures is to cover electrical components, cabinets for knobs and switches which cover the wirings of the house or office. The only part which is visible in the house or office is the enclosure, but not what is inside it.

Sometimes when people need to fix or cut a square hole in enclosures, they don’t really know which method to use. Most of them have the appropriate equipment at home for creating square holes in enclosure but don’t know how to make them, through the above stated two methods; you can easily create square holes in enclosures without spending an extra dollar.


Images: popularmechanics,,

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SIMCO Disclosures

We discuss all things to do with plastic enclsoures and thier applications in the electronics industry.