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How to cut a square in a blank panel with minimal tools?
How to cut a square in a blank panel with minimal tools?
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Old 12th June 2018, 07:11 PM   #21
russc is offline russc  England
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I usually draw panel holes/cutouts in CAD & print out.
1mm circle to indicate where to centre-pop.
3mm circle ensures the pilot drill hasn't wandered.
Then Pritt-stick to the panel. Small (3mm-ish) pilot drill first.
Easy if you have a manufacturers drawing of the piercing to work from.
Can be more difficult if measuring a component from life.
And do not assume anything - I was caught out by an LCD display - PCD holes were 0.3mm off-centre, it was shown on the drawing.
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Old 14th June 2018, 04:28 AM   #22
wayne is offline wayne  United States
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How to cut a square in a blank panel with minimal tools?
Decent files help . Mc Mastercar 5 piece set with handles iron oxide coated. About $ 65.00. Stepped hole saws from Harbor Frieght work okay in aluminum and are inexpensive on sale.
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Old 14th June 2018, 09:22 PM   #23
spaceistheplace is offline spaceistheplace
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How to cut a square in a blank panel with minimal tools?
Default How to cut a square in a blank panel with minimal tools?

Quote:
Originally Posted by jackinnj View Post
Nibbler tool -- about $7 -- I think you can find it at Parts Express etc.



You can also do it by drilling a series of small holes within the outline of the IEC socket, put the panel on a piece of wood and knock it out with a punch -- then file. The IEC power connectors I have used have 6 sides so you won't find a Greenlee punch for less than a few hundred dollars.

Thanks for that

Nickel Plated Nibbling Tool

IMG_9786.JPG

This looks to me like the most sensible, low cost solution unless Iím missing something.

PS OT I tried reaching out to you for some of SYís boards a long time back and never heard back. Did your inbox get full? PM me if you have the time.
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Old 14th June 2018, 10:37 PM   #24
chrisb is offline chrisb
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I've found the nibbler to be not as useful as I'd hoped - easily clogged, and my cheap one dulled quickly. Drilling that series of holes and filing out with a series of files seemed to work the best overall.
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Old 15th June 2018, 12:58 AM   #25
tapestryofsound is offline tapestryofsound  Scotland
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Quote:
Originally Posted by chrisb View Post
Drilling that series of holes and filing out with a series of files seemed to work the best overall.
This is what I learnt in metalwork class at school 50 years ago.
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Old 15th June 2018, 01:06 AM   #26
Dave Zan is offline Dave Zan  Australia
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Quote:
Originally Posted by spaceistheplace View Post
This looks to me like the most sensible, low cost solution...
Like ChrisB, I have a nibbler and it does not work well on material more than a millimetre or so thick.
Perhaps the one in your picture is better but I would drill and file too.
As several people have mentioned, take it slow and it's not hard to produce very tidy work.

Best wishes
David
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Old 15th June 2018, 02:39 AM   #27
spaceistheplace is offline spaceistheplace
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How to cut a square in a blank panel with minimal tools?
While looking for circular IEC outlets I came upon this:

Museum of Plugs and Sockets: IEC 60309 plugs and sockets

Leave it to the Dutch to have a museum devoted to plugs and sockets.

I will go slow and try the hole and file method
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Old 16th June 2018, 05:08 PM   #28
jackinnj is offline jackinnj  United States
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How to cut a square in a blank panel with minimal tools?
Quote:
Originally Posted by spaceistheplace View Post
Leave it to the Dutch to have a museum devoted to plugs and sockets.
If you're country was full of polders you'd have a museum full of plugs.

Click the image to open in full size.
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Old 16th June 2018, 09:51 PM   #29
PRR is offline PRR  United States
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Quote:
Originally Posted by chrisb View Post
...getting the second hole on a volume pot or selector switch's indexing / lock washer is fun
Drill big hole. Put pot in. Scratch the tab on the metal. Now you have the right radius.
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Old 17th June 2018, 05:05 PM   #30
AVWERK is online now AVWERK  United States
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Cover both sides with blue tape or use soft wood in a vise in what ever method you decide upon in cutting
A firm solid foundation is paramount in doing it right.
Drilling many small holes, jig saw, rotary file in a high speed drill, finishing up with a course file, they all work but, make it secure so it will not move and you will succeed

Regards
David
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