I used a Dremel 3000 to cut out a window out of 2mm thick aluminium, I went through about 3 very cheap discs and it took about 2 hours (the window was about 40cm x 40cm).
2 hours?!!!!! OMFG what the discs made of jelly?
I bought the lowest model, with carbon fibre cutting discs, dremel branded.
I practiced on an old computer case to get the lines straight and work out the most precise way to hold the tool.
After a couple hours of practice i then moved to the real one. I did it in 20 minute bursts, taking a short break each time till i was done.
Then onto the filing to make sure the edges are smooth.
Then put the rubber trim around the edge and tape in the perspex![]()