square hole...

[chrisatpsu]

any suggestions on creating a 1/2" square hole in the tip of the 1" pvc caps?

[sebjsan]

[nvizzini]

you can drill a 1/2 " hole and use a Small triangle file to
make it square
Nicholas

[mms]

A wood-worker's mortising bit would do the trick (it's a drill bit enclosed in a square chisel.) 

Harbor Freight has them.

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[zwiller]

Can't believe somebody beat me to the mortising bit idea...  Good job mms!  Must be a fellow woodworker...

[Dennis Cherry]

You could buy one of these.

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[chrisatpsu]

the judge will cut it for me?

[rrowan]

Just make a CNC machine like RJ did or buy a Laser cutter 

Ok, back to reality the mortise bit is a good idea and I have always wanted to try heating up a old chisel and push it into the plastic.

Rick R.

[craig d]

I drill a hole and use a square file , Craig

[chrisatpsu]

the hole and file idea might be my best bet. i dont have a mortise machine

[craig d]

Get one with the corse teeth (plasti-cut or bastard), not the fine ( mill file ) Craig

[tbone321]

You could buy one of these.

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What exactly dos this crap have to do with cutting a hole or with anything to do with this forum at all?

[mms]

the hole and file idea might be my best bet. i dont have a mortise machine

I think you can use a drill press, but I know Norm had a designated machine.

Zwiller:  I dabble.  My tool collection and project list grows, but my time doesn't!

[zwiller]

I think you need an attachment for a drill press.  No mortising jig here either. 

If I had to do a small number of such holes, I would grind the top of the cap flat if it is round, this should make it easier to work on and take most of the material away, drill 4 small holes in corners and finish straights with either a dremel with cutoff wheel or a sharp 1/2" chisel.  Clean with file if you don't have steady hands.    

Easy peasy japanesey.

mms: time will come.  I am not cranking out chippendale highboys, but I have made some nice pieces for the house and repaired many an antique.  Complimentary hobby for building blinky related stuff.  It better be, since "my" space in the garage is occupied by my shop...

[tbone321]

The downside to that is that most of those adapters will only fit on a full sized drill press and even if you could manage to fit it on a benchtop, you had better have the press clamped down to keep it from flipping off of the bench with the force you might need to apply to the handle.  I have one of those sets and have used it a few times but with the force I have to apply to my drill press to use it, I plan on buying a dedicated machine next year.  Maybe I can get it as a Christmas present from my wife.