Square holes in aluminium...

aardvarkash10 · 10th November 2009, 12:15 AM

neatly cutting square and rectangular holes for power IEC connectors and through-chassis transformers in alimunium sheet.

How do YOU do it?

Andrew Eckhardt · 10th November 2009, 12:17 AM

Depends on how many. If I had to do a lot I'd buy a threaded punch and die set.

MJL21193 · 10th November 2009, 12:20 AM

I use my Sylar finger

audi0 · 10th November 2009, 12:22 AM

For a one off, I mark out the shape of the desired hole, drill a series of small holes (almost touching) around the inside of the mark, remove the centre and file to shape.

audi0 · 10th November 2009, 12:38 AM

You could use one of these!

Andrew Eckhardt · 10th November 2009, 12:40 AM

Quote:

Originally Posted by audi0

You could use one of these!

Those should be banned!

MJL21193 · 10th November 2009, 01:20 AM

Aluminum is easy...try 16 gauge stainless:

Picture 1194.jpg
IM001623.JPG

Geek · 10th November 2009, 03:43 AM

If the chassis hasn't been bent yet, a scroll saw with a 28TPI twist blade.

If it has, draw the IEC hole template needed, 1/8" drill each corner (4-6), then dremmel with cutoff wheel (the real thin ones that come 20 per package)

Cheers!)

GK · 10th November 2009, 04:52 AM

Quote:

How do YOU do it?

Rectangular drill bit.

danielwritesbac · 10th November 2009, 05:18 AM

Quote:

Originally Posted by GK

Rectangular drill bit.

You made me snort! lol!

10th November 2009, 12:15 AM	#1
aardvarkash10 diyAudio Member Join Date: Mar 2007 Location: Auckland, NZ	Square holes in aluminium... neatly cutting square and rectangular holes for power IEC connectors and through-chassis transformers in alimunium sheet. How do YOU do it? __________________ Yes, conservatism thrives on low intelligence and poor information. But the liberals in politics... continue to back off, yielding to the supremacy of the stupid. It's turkeys all the way down. - George Monbiot, guardian.co.uk, 6 Feb 2012

10th November 2009, 12:22 AM	#4
audi0 diyAudio Member Join Date: May 2009 Location: 37.34 degrees South Blog Entries: 5	Square holes For a one off, I mark out the shape of the desired hole, drill a series of small holes (almost touching) around the inside of the mark, remove the centre and file to shape.

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10th November 2009, 12:17 AM	#2
Andrew Eckhardt diyAudio Member Join Date: Nov 2005 Location: PA	Depends on how many. If I had to do a lot I'd buy a threaded punch and die set.

10th November 2009, 12:20 AM	#3
MJL21193 Account disabled at member's request Join Date: Mar 2007	I use my Sylar finger

10th November 2009, 01:20 AM	#7
MJL21193 Account disabled at member's request Join Date: Mar 2007	Aluminum is easy...try 16 gauge stainless: Picture 1194.jpg IM001623.JPG

10th November 2009, 03:43 AM	#8
Geek diyAudio Member Join Date: Sep 2004	If the chassis hasn't been bent yet, a scroll saw with a 28TPI twist blade. If it has, draw the IEC hole template needed, 1/8" drill each corner (4-6), then dremmel with cutoff wheel (the real thin ones that come 20 per package) Cheers!)

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