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Old 30th October 2005, 05:50 AM   #11
Bill*B is offline Bill*B  United States
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Greenlee "730" chassis punches are great for tube sockets. They are expensive if purchased new, but are often offered at reasonable prices on eBay. Quick and precise.
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Old 30th October 2005, 09:38 AM   #12
SY is offline SY  United States
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I have Greenlee punches for octal, 9 pin, and 7 pin socket sizes. I got them for my 13th birthday, and after nearly 40 years and having built a few hundred tube projects, they still work perfectly.
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Old 30th October 2005, 10:03 AM   #13
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Until I can afford good punches, I use a 28TPI blade on my scrollsaw and lots of oil. keep it around 900 SPM or less for aluminum and other soft metals. Steel, forget it!

Regular twist drill bits (titanium with the most used ones being cobalt) for smaller holes (1/2" and less).
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Old 31st October 2005, 02:00 AM   #14
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I use a series of three different unibits to go up tp 1.25" , then Greenlee punches, or a verticle mill if the hole is rectangular.

Mark
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Old 31st October 2005, 02:38 AM   #15
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Quote:
Originally posted by SY
I have Greenlee punches for octal, 9 pin, and 7 pin socket sizes. I got them for my 13th birthday, and after nearly 40 years and having built a few hundred tube projects, they still work perfectly.
I broke the draw-bolt on my 7-pin Greenlee punch and have been looking for a replacement -- any suggestions.
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Old 31st October 2005, 03:44 AM   #16
Variac is offline Variac  United States
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Whenever using all these ideas that require a spinning blade on sheet metal be very sure the metal is anchored well. If not when the tool jams, the metal becomes a rotary saw on your fingers!!
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Old 31st October 2005, 09:12 AM   #17
SY is offline SY  United States
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Quote:
Originally posted by jackinnj


I broke the draw-bolt on my 7-pin Greenlee punch and have been looking for a replacement -- any suggestions.
Maybe McMaster-Carr?
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And while they may not be as strong as apes, don't lock eyes with 'em, don't do it. Puts 'em on edge. They might go into berzerker mode; come at you like a whirling dervish, all fists and elbows.
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Old 31st October 2005, 03:40 PM   #18
amperex is offline amperex  United States
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Default socket & transformer holes

For round holes I use Greenlee punches. Makes for an ultra clean hole & various sizes are perfect for most tube sockets.

As for square holes, I use a chassis 'nibbler' tool. It snaps out a small 1/8" x 1/4" piece at a time. Tedious, but does perform. After I am finished with the nibbler square hole, I use a flat file to smooth out each side of the square hole.

A nibbler tool can not cut steel easily that is thicker than about 20 guage. Aluminum is easy & any aluminum Hammond chassis is not a problem. Real square punches exist, but are terribly expensive.

If I was to mass produce tube gear, I would use a custom die & 30-50 ton press.
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Old 31st October 2005, 03:50 PM   #19
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time for some serious CNC discussion here -- I have a Grizzly mini-mill which the "young men" of the family purchased for me 2 Christmas' ago -- one of their friends, a CMU grad has adapted a bigger Grizly with XYZ stepper motors --

so you don't need a 30 ton punch press anymore -- but you will need to figure out how to translate your cad drawings.
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Old 31st October 2005, 10:15 PM   #20
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Quote:
Originally posted by jackinnj
... but you will need to figure out how to translate your cad drawings.
A handbook on Perl/Python/Tcl can be your best friend in such a case maybe
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