I used to mod MegaMan Battle Chips as a hobby. I'd buy a shit-ton of those NT Warrior Battle Chip 5-packs, cut them open with a utility knife and them mod the contacts so that they would act as different Battle Chips. I can totally sympathize, dude.
A bit more on-topic, what's your setup for cutting covers? Ruler and utility knife? You've illustrated why I don't do it that way.