how to cut HDPE

[Danjr1]

using 4 argos drill motors, whats the best way to cut the d shape needed to mount the motor into 20mm HDPE so that the gearbox shoulder actually sits in the HDPE? all ive got is corded and cordless drills, jigsaw and a bench drill

[daliad100]

You can draw the correct shape on the hpde/ make a paper template and chain drill out most of the material using the bench drill. Then you can clean up the hole using a saw of file.

Alternatively, drill a hole for the jigsaw blade to go into and cut out the correct shape

[widow_twanky]

I agree, just mark the shape and drill it out and then tidy it up afterwards.

[Chris230291]

I always find cutting plastics is easier with a wood blade in the jigsaw.

[typhoon_driver]

could always buy yourself a cheap hole saw kit off ebay and go straight though it with the pillar drill. I'd recommend going slightly smaller than you need and clean it up with a rounded edge file and make sure you use some lubricant when drilling!