I'm thinking ahead to an enclosure for an Arduino project I'm working on. Although I have not yet chosen a specific box, it will almost certainly be aluminum (somewhere around .050" thickness). There will be rectangular components (e.g., an LCD panel and a numeric keypad) mounted on the front panel of the enclosure, so I will need to cut rectangular holes. I do not have access to a machine shop (which is just as well, since I wouldn't know how to use it if I did).
Three possibilities come to mind for cutting the holes:
Remove most of the material with a Dremel tool using a fiberglass-reinforced cutoff wheel, then clean up with a file.
Drill holes (probably in the corners), then remove material with a hand nibbler tool, then clean up with a file. (I do not own a nibbler, but I'd be willing to buy one if that's the best tool for this job.)
Drill one or more holes, then remove material with a jeweler's saw (not sure what blade), then clean up with a file. (This may not be feasible; I haven't yet done the layout, so the saw may or may not have a deep enough throat to cut all of the holes.)
Any suggestions as to which of these alternatives (or any other ideas) would be best would be appreciated. Thanks.