How to make holes in plastic boxes?

OM2

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I need to make holes in plastic boxes.
The holes need to be clean and smooth ones.
I've drilled and it comes out looking like a big mess!
I need to be able to do many many times so need to figure out how to do in a quick and clean operation that only takes seconds.

See below for what I've done so far:
bBun9no.jpeg

Thanks.
 
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What sort of drill did you use? It must be cold.

1732542548433.jpeg
 
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Or use a Q-Max (or similar) cutter. Good, but expensive if you aren't using them a lot.
 
Piece of timber clamped inside the face of the box to drill into.
100% this

if you have loads make up 2 jigs
the face board needs to be deeper than the amount the drill point is protruding although once the wooden face discs have been cut out and removed from the face jig you dont need a auger/drill bit at all for holes sticking forward so can be cut short /retracted or removed dependent on design
this board can be cut to fit snugly between those ribs and the lip at the top
the inner one will be probably fitted to the width and base probably with shaped edges to locate accurately
you then with a solo clamp away from the drill area clamp them firmly together
the first 4 holes in situ will make the jigs complete as in the outer jig plate will now have a cut hole with a auger/drill hole on the inner plate
once set up you will only have to empty the hole saw off plastic discs every few boxes at the point the cutting teeth have less than 5mm behind them full off plastic
 
Last edited:
If you're using a dril like John pictured in #2, run it backwards, and make sure the plastic is warm

Prefer Mottie's suggestion. But looks like you could get away with smaller holes; try using a soldering iron?
 
an adjustable hole saw may work well from both sides but will take ages,and not pushing too hard

although the ribs on the outside off the box may get in the way if the cover is fitted
 
Thanks for the replies guys.
Hot rod I would consider something similar like a soldering iron.
But would prefer drilling
The drill I uses was a wooden drill bit. If I used another type, maybe would be better?
Adding wood sounds perfect - but then how do I do the same job again 100 times?

100% this

if you have loads make up 2 jigs
the face board needs to be deeper than the amount the drill point is protruding although once the wooden face discs have been cut out and removed from the face jig you dont need a auger/drill bit at all for holes sticking forward so can be cut short /retracted or removed dependent on design
this board can be cut to fit snugly between those ribs and the lip at the top
the inner one will be probably fitted to the width and base probably with shaped edges to locate accurately
you then with a solo clamp away from the drill area clamp them firmly together
the first 4 holes in situ will make the jigs complete as in the outer jig plate will now have a cut hole with a auger/drill hole on the inner plate
once set up you will only have to empty the hole saw off plastic discs every few boxes at the point the cutting teeth have less than 5mm behind them full off plastic
Any chance of a video? :)
Really complex and hard to follow
Thanks
 

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