How to drill 4 mm holes in 1 mm. Steel and avoid grates?

[russc]

Cut a big hole & cover with perforated metal.

 

[tomchr]

Where did you get the volume knob you showed in the video on deburring above? Movishop? Novishop?

ModuShop: www.modushop.biz

Tom

 

[Pars]

Ahh, Modushop. Thanks!

 

[Ben Mah]

Stepped bits have also worked for me for drilling into thin sheet metal - round holes every time versus jagged holes with regular bits.

I have a set of stepped bits that start at 3mm diameter.

 

[gijser]

To get a nice clean hole, I drill to about 3/4 of the thickness and then the last bit from the other side.

 

[Ben Mah]

That's hard to do when drilling thin material.

 

[OSLO]

Thanks all. Wish I had taken metalshop in school 😉

 

[OSLO]

I found the single flute type a better choice for me. Works smoothly in a hand held drill or drill press.


Single Flute Countersink

Is it possible to get a 4 mm. single flute drill for the actual hole drilling ? I understand that it should put less stress/heat in the actual drilling ?

 

[OSLO]

If you're gonna drill: start with a 3mm (1/8") bit. Use cutting oil, 3-in-1, something. After making the first hole with a twist bit, get a Step Bit to make the larger holes. A twist bit will bend thin sheet metal as it goes in, don't use big twist bits on thin sheet metal. There are many deburring tools out there, for sheet metal I like to use a Countersink Bit, but not one with flutes, they chatter. Use one with a hole through it, like this:

View attachment 1317143


This will give you the smoothest edge.

Try to practice a couple cuts on similar material, if possible. Go slow. Have fun!

w

Thanks. What deburring countersink bit SIZE would you recommend for a 4 mm. hole ?

 

[OSLO]

I have this angler, but it takes umbraco bits

 

[JMFahey]

That many holes?
Sorry but not doable by hand, even with a bench drill, because 4mm twist drill is too thin and flexes, so you will lose alignment
Proper solution is punching them.

Plan B is to cut a window the size of the whole ventilation area, say 5 by 10 cm or whatever you need, it will be easier to get clean edges or worst case file them down, and cut a proper sized rectangle out of commercial perforated sheet (which is punched) and resistance spot solder or worst case Epoxy it in place.

Spray painting everything in semi-gloss black paint will disguise any small imperfections.

We are talking home accessible solutions here, the chassis you show was CNC punched before final bending and painting.
.
.

 

[Randy Bassinga]

Plan B is to cut a window the size of the whole ventilation area, say 5 by 10 cm or whatever you need, it will be easier to get clean edges or worst case file them down, and cut a proper sized rectangle out of commercial perforated sheet (which is punched) and resistance spot solder or worst case Epoxy it in place.

I call these inlays. Another reason to just DIY the whole case in the first place with a basic desktop CNC

 

[OSLO]

I would only use the angler for deburring with a countersink

 

[dubadub]

@OSLO I will share the links, but I don't know if you can purchase them from overseas. but you know what they look like now 😉

19mm countersink with Hex shaft from Amazon - use with your angler and drill/impact. carefully.

KEO 53511 Cobalt Steel Single-End Countersink, Uncoated (Bright) Finish, 82 Degree Point Angle, Round Shank, 1/4" Shank Diameter, 3/8" Body Diameter this type stays seated and centered in the hole much better than the fluted types. cleaner results.

 

[OSLO]

Could I use this HSS single flute milling bit for drilling 4 mm. holes in the 1 mm. steel plate (using a Shapeoko CNC) ?
https://cnc-plus.de/en/end-mills-di...e-milling-bit-end-mill-4-00-mm-15-coated.html

 

[dubadub]

it looks the part, but I only know hand tool stuff...

 

[vinylkid58]

Could I use this HSS single flute milling bit for drilling 4 mm. holes in the 1 mm. steel plate (using a Shapeoko CNC) ?

I'm going to say no, but I've never even seen one of those before. Looking at the length, there's a good chance it will just break.

If you're using a CNC, then just use proper drills or slot mills.

jeff

 

[WntrMute2]

I'd suggest the simple stepdrill bit. They can be had in single as well as dual flute versions. The self deburr is a plus.

 

[tomchr]

Could I use this HSS single flute milling bit for drilling 4 mm.

Sure. If you have flat sheet and a vacuum chuck... 🙂 If all you have is hand tools you'll probably lose a finger.

Tom

 

[tomchr]

Plan B is to cut a window the size of the whole ventilation area, say 5 by 10 cm or whatever you need, it will be easier to get clean edges or worst case file them down, and cut a proper sized rectangle out of commercial perforated sheet (which is punched) and resistance spot solder or worst case Epoxy it in place.

Pretty good plan in my view. You can also attach it with screws. It can be made to look nice.

Tom