How do I cut a square out of aluminum?

TheDriver41 · 20th October 2004, 10:44 PM

How do I cut a square out of aluminum?

I figure I can just use drill bits for circles. But I need to cut out a square for the ac input.

Thanks,
Matt

Vikash · 20th October 2004, 10:51 PM

Cut a round hole with a drill bit, then you can jigsaw, bandsaw, scrollsaw, hacksaw, or manually file it down. Surely not that difficult?

TheDriver41 · 20th October 2004, 10:54 PM

Quote:

Originally posted by Vikash
Cut a round hole with a drill bit, then you can jigsaw, bandsaw, scrollsaw, hacksaw, or manually file it down. Surely not that difficult?

That what I was thinking. I didn't know if a special tool exist.

Thanks,
Matt

x. onasis · 20th October 2004, 10:58 PM

What tools do you have?

Drill a series of holes and shape the edges with a file....

You could drill the corners and connect them with a jeweler's saw, or a coping saw, or any reciprocating saw (like a jig saw)

Clamp or screw a jig saw upside down to a board and it mades a decent table set up for very accurate cuts. Clamps, weights and sometimes padding work well to absorb vibrations.

A pneumatic die-grinder works pretty well too.

thomas997 · 21st October 2004, 04:43 AM

If the aluminum is very thin, a square punch probably exists..

fcel · 21st October 2004, 04:48 AM

Answer is somewhere in this thread ..... Useful tools and techniques

dnsey · 21st October 2004, 06:53 AM

Punches are indeed available, but they're not particularly cheap.
A 'nibbler' tool's a good investment (either a manual one, or the kind that fits a pistol drill). Good for all kinds of jobs like this!

garbage · 21st October 2004, 01:21 PM

Quote:

Originally posted by TheDriver41
How do I cut a square out of aluminum?

I figure I can just use drill bits for circles. But I need to cut out a square for the ac input.

Thanks,
Matt

there's a tutorial here that uses almost every day parts.

TheDriver41 · 21st October 2004, 03:44 PM

Thanks for the input guys. I have four shipments coming. I have already received about 6 so far for this project. I’ve spent about $600 in tools and stock pills of parts. I should have everything done with the amp in about a week or so. My speaker won't be here till around 11/10.

Real dumb question: The switch I'm using for power has three terminals. Is one a ground? Do I use all three?

Vikash · 21st October 2004, 04:18 PM

yes!

20th October 2004, 10:44 PM	#1
TheDriver41 diyAudio Member Join Date: Sep 2004 Location: iowa	How do I cut a square out of aluminum? How do I cut a square out of aluminum? I figure I can just use drill bits for circles. But I need to cut out a square for the ac input. Thanks, Matt

20th October 2004, 10:51 PM	#2
Vikash diyAudio Moderator Emeritus Join Date: May 2003 Location: UK	Cut a round hole with a drill bit, then you can jigsaw, bandsaw, scrollsaw, hacksaw, or manually file it down. Surely not that difficult? __________________ "The human mind is so constituted that it colours with its own previous conceptions any new notion that presents itself for acceptance." - J. Wilhelm. (But I still think mine sounds better than yours.)

20th October 2004, 10:58 PM	#4
x. onasis diyAudio Member Join Date: Jan 2003 Location: NYS	What tools do you have? Drill a series of holes and shape the edges with a file.... You could drill the corners and connect them with a jeweler's saw, or a coping saw, or any reciprocating saw (like a jig saw) Clamp or screw a jig saw upside down to a board and it mades a decent table set up for very accurate cuts. Clamps, weights and sometimes padding work well to absorb vibrations. A pneumatic die-grinder works pretty well too. __________________ onasis

21st October 2004, 04:18 PM	#10
Vikash diyAudio Moderator Emeritus Join Date: May 2003 Location: UK	yes! __________________ "The human mind is so constituted that it colours with its own previous conceptions any new notion that presents itself for acceptance." - J. Wilhelm. (But I still think mine sounds better than yours.)

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21st October 2004, 04:43 AM	#5
thomas997 diyAudio Member Join Date: Feb 2004 Location: Vancouver	If the aluminum is very thin, a square punch probably exists..

21st October 2004, 04:48 AM	#6
fcel diyAudio Member Join Date: Sep 2001 Location: LA County	Answer is somewhere in this thread ..... Useful tools and techniques

21st October 2004, 06:53 AM	#7
dnsey diyAudio Member Join Date: Mar 2004 Location: Shropshire, England	Punches are indeed available, but they're not particularly cheap. A 'nibbler' tool's a good investment (either a manual one, or the kind that fits a pistol drill). Good for all kinds of jobs like this!

21st October 2004, 03:44 PM	#9
TheDriver41 diyAudio Member Join Date: Sep 2004 Location: iowa	Thanks for the input guys. I have four shipments coming. I have already received about 6 so far for this project. I’ve spent about $600 in tools and stock pills of parts. I should have everything done with the amp in about a week or so. My speaker won't be here till around 11/10. Real dumb question: The switch I'm using for power has three terminals. Is one a ground? Do I use all three?

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