Cutting IEC Socket in Chassis - Page 3

gpecke · 30th January 2011, 06:05 AM

Dremel with cutting disk on high speed takes about 2 mins on thin sheet steel. Needs about 4 disks, and safety glasses are essential since the disks
can fly off in pieces.
Black Russians greatly improve the smoothness of the cut.

VictoriaGuy · 30th January 2011, 07:25 AM

Abrasive cutting disks don't work well with aluminum. (Remember metal shop? Touching the grinding wheel with aluminum would get you in BIG trouble...).Even with steel, I find 'em a bit scary.

Drill, jigsaw and a bit of file work will do the job on steel. Hand nibbler is good with aluminum- I'm pretty sure my cheap nibbler wouldn't handle steel.
If you think it should take you 5 min, it's a real PITA. If you relax and figure it will take 20-30 min to do a proper job, no problem.
Anyway, the flange on the jack will hide some small mistakes. And you can make big holes smaller with Bondo.....
;-)

MJL21193 · 30th January 2011, 12:24 PM

Quote:

Originally Posted by gpecke

If you want to cutout a rectangle in a hard material such as steel, a small grinding disk in Dremel or equivalent does a good job.

Done with the Dremel:

NPX_01185.JPG

16awg stainless steel. Used less than one thin disk.

Aluminum:

_0035.JPG

The square switch cutouts were done with the Dremel and touched up with a file. Used 2 disks, one for each cutout.
Like all tools, it takes practice to get good results.

Dragondreams · 30th January 2011, 01:36 PM

I've never thought of any other way than doing it with a Dremel. The price of a punch buys an awful lot of cutting discs...

I cheat a little and print out the cutting template on to self-adhesive labels, then follow the lines closely. Now that I've had a bit of practise, I can usually get away without filing anymore.

Marra · 30th January 2011, 02:09 PM

I usually drill four holes then cut the shape out using a carbide hacksaw blade[the type usually used for cutting shapes in ceramic wall tiles] and then finish to size with a file. The carbide blade seems to work well with up to 3mm aluminium. I no longer use steel.

dwell · 30th January 2011, 08:46 PM

For aluminum chassis I have had good luck using a coping saw with a fine tooth blade. I usually go to the IEC socket manufacturers website and print out the dimensioned drawing of the hole cutout at 1:1 and tape it to the chassis to use as a template. Drill a couple holes to pass the coping saw blade through and cut your hole. Minimum filing required if you take your time with the cut.

Good luck

30th January 2011, 06:05 AM	#21
gpecke diyAudio Member Join Date: Jan 2011	IEC cutout Russian style. Dremel with cutting disk on high speed takes about 2 mins on thin sheet steel. Needs about 4 disks, and safety glasses are essential since the disks can fly off in pieces. Black Russians greatly improve the smoothness of the cut.

30th January 2011, 01:36 PM	#24
Dragondreams diyAudio Member Join Date: Dec 2010 Location: Normanton, West Yorkshire	I've never thought of any other way than doing it with a Dremel. The price of a punch buys an awful lot of cutting discs... I cheat a little and print out the cutting template on to self-adhesive labels, then follow the lines closely. Now that I've had a bit of practise, I can usually get away without filing anymore. __________________ Experience is what teaches us to make a different mistake next time...

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30th January 2011, 07:25 AM	#22
VictoriaGuy diyAudio Member Join Date: Dec 2008 Location: Victoria, BC	Abrasive cutting disks don't work well with aluminum. (Remember metal shop? Touching the grinding wheel with aluminum would get you in BIG trouble...).Even with steel, I find 'em a bit scary. Drill, jigsaw and a bit of file work will do the job on steel. Hand nibbler is good with aluminum- I'm pretty sure my cheap nibbler wouldn't handle steel. If you think it should take you 5 min, it's a real PITA. If you relax and figure it will take 20-30 min to do a proper job, no problem. Anyway, the flange on the jack will hide some small mistakes. And you can make big holes smaller with Bondo..... ;-)

30th January 2011, 02:09 PM	#25
Marra diyAudio Member Join Date: Nov 2009 Location: Near Lincoln	I usually drill four holes then cut the shape out using a carbide hacksaw blade[the type usually used for cutting shapes in ceramic wall tiles] and then finish to size with a file. The carbide blade seems to work well with up to 3mm aluminium. I no longer use steel.

30th January 2011, 08:46 PM	#26
dwell diyAudio Member Join Date: Jan 2008	For aluminum chassis I have had good luck using a coping saw with a fine tooth blade. I usually go to the IEC socket manufacturers website and print out the dimensioned drawing of the hole cutout at 1:1 and tape it to the chassis to use as a template. Drill a couple holes to pass the coping saw blade through and cut your hole. Minimum filing required if you take your time with the cut. Good luck

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