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Old 9th January 2003, 11:24 AM   #11
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The very simple step drill that pinkmouse mentioned is a very cheap way of getting the job done. They generally cost less than $30.00 if cost is an issue. In addition to cutting the hole they can also deburr the opposite side when you turn it over. I have punches I could use but I prefer to use the step drill for this operation.

Joe
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Old 9th January 2003, 05:27 PM   #12
dhaen is offline dhaen  Europe
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Default Just to give you another possibility:

I have recently cut some large ~70mm holes in 6mm aluminium.
I used a "fly cutter", at least that's the UK name.

You need a "pillar drill" (drill press). It must be run at the lowest speed.

It was necessary to bolt the workpiece to an MDF base, and to flip and cut from each side, (changing sides at half time)

The results are good, but I wouldn't recommend it for "normal" chassis work, just for thick material, or holes too large to punch.
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Old 11th January 2003, 05:55 PM   #13
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Hi,

I have had good luck with a circle cutter for big holes and unibits for the smaller holes.

Click the image to open in full size.

Click the image to open in full size.

ck
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Old 11th January 2003, 06:23 PM   #14
dhaen is offline dhaen  Europe
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Nice.
How thick was the material.
Was it aluminium?
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Old 11th January 2003, 06:32 PM   #15
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Thanks,

Top plate was .090" brushed aluminum. Seemed to cut real easy. When finished, I hit with steel wool in same direction as brushed to blend in any scratches.

ck
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Old 11th January 2003, 06:38 PM   #16
dhaen is offline dhaen  Europe
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Hi ck,

What's your project?
Looks like a pair of monoblocks.
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Old 12th January 2003, 03:55 AM   #17
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Hi John,

I built a pair of JE Labs 300B's . This was my first DIY and am very pleased with the results.


Here is a link to my site with a few notes and pictures: Tube Stuff

Regards,
ck
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Old 12th January 2003, 10:07 AM   #18
dhaen is offline dhaen  Europe
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Hi ck,

Nice site. I rewcognise your pictures. Perhaps I've visited before.

Are you pleased at how it sounds?

Cheers,
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Old 21st December 2004, 04:38 AM   #19
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Hi,
I just read the instruction manual from Greenlee for thier knockout punch set.
It says that you can punch through up to 3.5mm or 10GA aluminum by hands...
Well, I am currently involved with holemaking work, but I really don't think it's feasible.
Has anybody succeeded before?
Thanks.
Lhchen
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Old 21st December 2004, 04:45 AM   #20
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Hi,

Quote:
Has anybody succeeded before?
Sure enough...

Even through 3.5 mm steel if must be but it would kill the punches if you'd do that regularly.

Aluminium, however, is pretty soft and the Greenlees go through it like a knife through butter.

Cheers,
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