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Old 10th November 2009, 12:15 AM   #1
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Default 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?
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Old 10th November 2009, 12:17 AM   #2
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Depends on how many. If I had to do a lot I'd buy a threaded punch and die set.
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Old 10th November 2009, 12:20 AM   #3
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I use my Sylar finger

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Old 10th November 2009, 12:22 AM   #4
audi0 is offline audi0  Australia
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Default 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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Old 10th November 2009, 12:38 AM   #5
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Default Hand nibbler

You could use one of these!
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Old 10th November 2009, 12:40 AM   #6
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Quote:
Originally Posted by audi0 View Post
You could use one of these!
Those should be banned!
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Old 10th November 2009, 01:20 AM   #7
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Aluminum is easy...try 16 gauge stainless:

Picture 1194.jpg
IM001623.JPG
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Old 10th November 2009, 03:43 AM   #8
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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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Old 10th November 2009, 04:52 AM   #9
GK is offline GK  Australia
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Quote:
How do YOU do it?

Rectangular drill bit.
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Old 10th November 2009, 05:18 AM   #10
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Quote:
Originally Posted by GK View Post
Rectangular drill bit.
You made me snort! lol!
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