Quote:
Originally Posted by turretslug
Chain-drilling a rectangle and dressing the hole to size with a file will likely take less time than reading and digesting this thread!
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True.
It took me no more than 15 minutes to cut a 1" x 1.5" slot in a piece of 1/8" scrap aluminium.
Drilled the holes with a 5mm drill in a pillar drill - no need to be too neat so long as the holes are within the lines.
Removed the waste.
Neatened up the hole with 20cm long coarse and fine files, each with one 'safe' edge.