While on vacation, I swapped my PDA flip cover for a hard case. Overall I like the case better, but one of my gripes was there was no opening for the headphone jack.
So this morning I rummaged through my tool box and found a round hand file. After about 10 mins of scraping I had carved out enough material for the jack to fit neatly. Needless to say, I took the PDA out of the case before filing. Overall, I found the process to be fun.