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Posted

measure, measure, and measure again to make sure your sides are even... tape them off and use a cutoff wheel and leave just a tiny bit of material to file off.  File it down perfectly straight and even from side to side and "polish" the edge back up with a heat gun

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Posted

Dremel with plastic cutting wheel, tape the line, cut slowly and precise, once done pull tape and hit the edges with a pencil torch (take your time to get the feel for how much flame is needed to form the edges.

 

 

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Posted

Look at pictures of one you like and then tape them off with masking tape like mentioned.  I actually used a jigsaw with a good sharp fine blade on it and a belt sander and a sanding block to make sure they were straight, but i was painting mine.  I have actually seen and would like to try sometime a cutting attachment for my soldering iron (the trigger style with 2 ends coming from the tip) as i think it would be like cutting butter with a hot knife.

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