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Tips for making a Still Air Box SAB

Mushyluv's porthole glove box kit. White. Installed in an SAB-mini still air glove box.

Begin by determining if you want your lid to be the top or bottom of your SAB. Orient your tote accordingly.

Note: Due of the rounded edges common to most totes used for SABs, It’s important you don’t install your ports any closer than 3/4″ from the edge of your tote. The cutout template makes it easy to visualize how your ports will look installed and any safe cutting distances.

Select the the distance apart for your arm ports (Relative to the floor of your SAB)

Mark the desired centers of your arm ports. You can use your cutout template to help visualize where your arm ports will fit best. Draw the port hole circle cut out guides onto your SAB with a sharpie using the template.

How do I cut out ports for my still air box?

Note: Cutting polypropylene and polyethylene totes can be a tricky. They have a tendency to crack and split when drilling or cutting. The following suggestions can help minimize  chances of splitting.

ez-SAB-port cut out template download (a preprinted template is included with your order as well.)Mushy Icon
When printing the cut out template, It’s important you tell the acrobat print dialogue to print “Actual size“. This insures the template is dimensionally correct. Test your template by placing it over your port threads.

The two options that are the least likely to cause cracking and splitting when cutting out your sab port holes:

Hot knife for cutting Still Air Box
Hot Knife sab port plastic cutter tool. (safest) #ad
4.5" 115mm still air box arm port hole saw.
4.5″ 115mm still air box arm port hole saw. (quickest) #ad

Hot Knife:

plastic build up around port hole after hot knife cut
Click to enlarge

You may notice plastic build up occurring on either side of your cut.  Once the newly cut port hole has cooled to room temp, take a razor blade or sharp utility knife and run it along the edge of your port hole.  Be especially careful not to cut yourself. The razor blade should trim off the excess leaving a noticeably cleaner edge around your port hole.

4.5″ (115mm) hole saw

When using a hole saw always make sure the tote’s surface you are drilling into is supported by wood or similar sturdy material underneath. Very important to prevent cracking.  If the hole saw binds when drilling out the arm port, stop and clear the cut of debris. Re-center your hole saw and complete the cut with the drill in reverse.

The Next safest bet in cutting out your port holes:

3.) Drill (a bunch of) tiny holes into the sharpie circle outlines you drew on your SAB. The smaller the drill bit the better and the more holes the better. Think 7/64″ or smaller on the drill bit. Be careful when drilling not to apply too much pressure to the bit.  Excessive bending of the plastic could lead to a split.

Two options:

A) Cut between the holes with a heated utility knife. Place the blade of the utility knife over a candle, cigarette lighter, or similar heat source then drag the heated knife cutting hole-to-hole until it cools and stops cutting. Re-heat the knife blade and continue the process until you’ve cut out the entire circle.

B) Clip between the holes (if you’ve drilled them close enough together) using flush cutter snips such as these: (#ad)

This is a tedious process and will produce a ragged edged hole. No problem, simply clean up the hole as best you can pulling off any loose plastic bits from the process. As long as you don’t go way outside the template lines, the lip of your ez-SAB-port will cover up the ragged edges beautifully.

Install guides for optional glove port configuration :

elbow length Poly gloves (included): ez-SAB-glove install guide
Latex gloves (not included): – Latex glove install guide

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