I need to cut two small rectangular holes side by side in the right side of a Nordic Rage dash to mount switches. The factory switch design does not have much of a flange to cover hole cutting irregularities and the switch attachment design is such that the hole size must be accurate.

To make matters worse the location is up next to and partially under the windscreen such that a typical electric Sabre saw can not get under the wind screen, which is not removable unless you want to overhaul the entire interior.

The factory uses a small compact air saw for such work. The boat is in a dock with no compressed air available.

Any ideas on how to accomplish cutting these holes to necessarily accurate dimensions is solicited.

drill the corners and then a good dremel ?

drill either a series of small holes to ruff in out or 2 or 3 big holes whithin the area to be removed than fine tune it with a piece of wood kinda of like narrow a paint stick with PSA 80 grit sandpaper wraped around it. no herry so take your time and check for fit often.

Use a body saw/air saw....maby at a local pawn shop or u can order it from sears...
I am a x car audio installer and have done many boats a body saw is the only tool for the job!!!!!

Get Air To The Dock!!!!!!! :d

i think this hole is probably to small for a body saw. i really think you should sneak up on the hole by the method i described. the shoulder on that swich dosent leave much of a margin for error. the body saw is great for everything else though. dont know what i'de do without mine

What GlassDave said and then tune it with the Dremel .....they even have a cable for a dremel for close work ...I have a cordless one and does well .

Thanks guys!

Ever try a rechargable angle grinder with a small drum sander? Use Daves trick for the hole and heed the advice about checking fit often!

Hello Guys
The tool that is required is called a multi master Manufacturered by a company called Fien .
This little baby can cut accurate holes in most materials.
It is a totally fantastic piece of kit it oscillates at 21000 rpm .
As you will see the jobs this tool can do is really amazing , i would not be without one .Cutters down to 1cm ,switch holes a piece of cake !
www.feinmultimaster.co.uk I feel sure this must be available in the States.
Regards
Carl