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Old 19th March 2013, 12:15 AM   #11
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Thanks for pointing out the itsy-bitsy-tiny-winy (never mind the rest of the song) marks on the great Greenlee punches. In all the instructions that came with my sets (5/8" to 2" conduit) was their a mention of that mark I (re-reading) noticed. 25 years and counting!
I normally drill the hole to fit the bolt size accurately, than "unscrew" the slug out of the die. Lots of lubricant used to protect the Grade 8 (or better) steel used in the screw.
Anything smaller than 5/8" I pre-drill to max, and than ream and file to size.
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Old 21st March 2013, 01:27 AM   #12
Jsixis is offline Jsixis  United States
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1/8" I would definitely use a drill, punch would warp the box too much
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Old 21st March 2013, 03:08 AM   #13
Lavcat is offline Lavcat  United States
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The panel does not feel to me like it would warp. Not sure though. Here is a link to the drawing:

http://www.hammfg.com/files/parts/pdf/RM2U19BKFP.pdf


My worry is that if I drill the half inch holes I will get burrs but if I punch the holes I will not be able to achieve the positional accuracy I need. I am leaning towards drilling.

In any event I will have to punch the larger holes for the panel as I do not have equipment that can drill a 15/16ths hole. However for the 15/16ths holes I do not need as much accuracy as for the half inch holes.
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Old 21st March 2013, 03:41 AM   #14
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I purchased a set of nice carbide hole saws specifically for making knock out size holes. One of the electrical supply houses had them, pitched the greenlee ( they were dull). A step bit also is a good alternative that leaves a clean hole very versatile tool.

Bill
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Old 21st March 2013, 06:50 PM   #15
Lavcat is offline Lavcat  United States
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Rather than anything fancy I ordered HSS TiN coated 135 deg split point bits: 1/4 inch for the half inch punch pilot hole, 3/8 inch for the 15/16ths pilot hole, and 1/2 inch, should I decide to drill the 1/2 inch holes.

I plan to punch the 15/16ths holes, see how it goes, then either punch or drill the 1/2 inch holes, depending. Sadly I have a taste for expensive bits but I hope the HSS will make acceptable holes here.

I have never used a hole saw. I googled around a bit but did not find a carbide hole saw as small as half an inch.
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Old 5th April 2013, 04:34 PM   #16
Lavcat is offline Lavcat  United States
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Yesterday I punched one of my 15/16ths holes in 1/8 inch die cast aluminum. It was quite a bit of work, and I almost gave up. But the hole looks very nice. I had no trouble unscrewing the bolt from the slug and die.


The problem is the slug is wedged in the die and I cannot get it out. Anyone have suggestions?
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Old 5th April 2013, 06:10 PM   #17
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drill a hole the exact size of the greenlee screw
assemble the punch on the chasis
use a pencil to mark where the punch is on the chasis
take apart punch
drill bigger centre hole
reassemble punch, align and punch
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Old 5th April 2013, 06:17 PM   #18
SY is offline SY  United States
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Quote:
Originally Posted by Lavcat View Post

The problem is the slug is wedged in the die and I cannot get it out. Anyone have suggestions?
If you didn't oversize the center hole, you can sort of thread the bolt back in a few turns, then whack the bolt head on the floor.
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Old 5th April 2013, 07:14 PM   #19
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Quote:
Originally Posted by SY View Post
If you didn't oversize the center hole, you can sort of thread the bolt back in a few turns, then whack the bolt head on the floor.
That's how I have always done it. Just seemed logical

Anyone have any advice as to how to avoid the paint flaking around the punch hole on the Hammond black powdercoat steel chassis? I normally cover the chassis in blue painters tape for marking all of my holes but that does not help much..

(Hope this is not thread-jackin'?)
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Old 6th April 2013, 12:07 AM   #20
Lavcat is offline Lavcat  United States
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Quote:
Originally Posted by SY View Post
If you didn't oversize the center hole, you can sort of thread the bolt back in a few turns, then whack the bolt head on the floor.
Wow, thanks! (Except instead of the floor I put the die in a vise and tapped the bolt with a rubber mallet.) I am embarressed I did not think of this myself.

My aluminum panel is Hammond black powdercoat but I did not notice any flaking.
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