Square holes in aluminium...

aardvarkash10 · 9th November 2009, 11:15 PM

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

How do YOU do it?

Andrew Eckhardt · 9th November 2009, 11:17 PM

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

MJL21193 · 9th November 2009, 11:20 PM

I use my Sylar finger

audi0 · 9th November 2009, 11:22 PM

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 · 9th November 2009, 11:38 PM

You could use one of these!

Andrew Eckhardt · 9th November 2009, 11:40 PM

Quote:

Originally Posted by audi0

You could use one of these!

Those should be banned!

MJL21193 · 10th November 2009, 12:20 AM

Aluminum is easy...try 16 gauge stainless:

Picture 1194.jpg
IM001623.JPG

Geek · 10th November 2009, 02:43 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, 03:52 AM

Quote:

How do YOU do it?

Rectangular drill bit.

danielwritesbac · 10th November 2009, 04:18 AM

Quote:

Originally Posted by GK

Rectangular drill bit.

You made me snort! lol!

9th November 2009, 11:15 PM	#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? __________________ "Folks, you can't prove truthiness with information. You prove truthiness with more truthiness. In a process known as truthinessiness." - Stephen Colbert, The Colbert Report

9th November 2009, 11:22 PM	#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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9th November 2009, 11:17 PM	#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.

9th November 2009, 11:20 PM	#3
MJL21193 Account disabled at member's request Join Date: Mar 2007	I use my Sylar finger

10th November 2009, 12:20 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, 02:43 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!)