Best way to make a dna20 screen sized rectangle in aluminum?

[testdruif]

Hey there handymen and women

Just wondering if anyone knows a great way or has experience with how to make a tiny rectangular "window" for showing that little dna20 screen.
The material I have at hand to make this rectangular shape in is aluminum.

Thanks in advance for being able to pick your brain(s)

[markm]

drill a small hole then a jewellers fret saw, followed by needle files to clean it up.

[raid2506]

DREMEL POWERS ACTIVATE!!!

[raid2506]

testdruif, transfer the outline by laying a piece of paper over the screen and rubbing around the edge with a pencil,

Cut the rectangle out with a blade and the lay paper on aluminium and colour in the hole with a marker.

Follow markm's advice to cut hole.

Finish by clamping aluminium in a vise and buffing edges of hole at 45° by pulling strips of sandpaper back and forward through hole.

Should give a nice rounded edge to the outside.

[testdruif]

I was wondering about the below method: (in case anyone tried it and it failed)

Transfer the outline to the aluminum
With a nice diameter drill, drill holes next to each other to get the saw blade (like little shark teeth) edge.
And if it's not straight or too ugly file things down.

[raid2506]

Yeah that would work, but.....

If you don't have a drill press and a sliding clamp the edge could be very nasty!

[testdruif]

Aug 27, 2013 8:40:32 GMT raid2506 said:

Yeah that would work, but.....

If you don't have a drill press and a sliding clamp the edge could be very nasty!

I recently acquired such a device
a steal really, used drill press with sliding clap for 15€ ^^

[raid2506]

Wow testdruif, that is a good price!