I have a small prototype circuit that's going to a client, that I'm putting in a repurposed acrylic plastic enclosure which I have several of. Due to the geometry involved, several of the 1/4th inch jacks have to sit right next to the joint where the main part of the case connects to the lid. I've been drilling the practice enclosure with hand tools, and I guess due to the type of acrylic, each time the drill bit cuts through to the other side of the material, the little lip of material between the hole and the box edge cracks or shatters. It's pretty annoying.
Is there a way to avoid this?