How to cut a square in a blank panel with minimal tools?

[russc]

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.

 

[wayne]

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.

 

[spaceistheplace]

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



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

PS OT I tried reaching out to you for some of SY’s boards a long time back and never heard back. Did your inbox get full? PM me if you have the time.

 

[chrisb]

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.

 

[tapestryofsound]

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.

 

[Dave Zan]

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

 

[spaceistheplace]

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

 

[jackinnj]

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.

An externally hosted image should be here but it was not working when we last tested it.

 

[PRR]

...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.

 

[AVWERK]

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

 

[codewritinfool]

Drill a hole and use a nibbler tool.

 

[scottjoplin]

I think that's been suggested before, has anyone advised using a hammer and chisel?

 

[chrisb]

Rough cut with acetylene torch and finish off with diamond nail file?

 

[scottjoplin]

Now you are being silly, I was being serious, kinda..........

 

[russc]

Be careful with that torch on a diecast enclosure, you might end up with no enclosure!

 

[tapestryofsound]

I think that's been suggested before, has anyone advised using a hammer and chisel?

I wouldn't advise using a hammer and chisel

Nice and slow with a drill and small holes, cut between holes with a coping saw, and finish off with files. Best with hand tools, and accuracy to 1/100th inch is entirely possible.

But a hammer and chisel could be fun ........

tapestryofsound

 

[DPH]

I think that's been suggested before, has anyone advised using a hammer and chisel?

Typically I go out to the garden looking for the sharpest, hand-holdable rock and go to town.

 

[Elvee]

I wouldn't advise using a hammer and chisel

I was the one suggesting it, and I can assure you that it can be very fast and very neat; of course, it can also end up in a horrible mess even faster, which is why I advised some practice before committing to a real job.

In general, fast and powerful techniques have a larger potential for huge and irretrievable mistakes: if you do all the work using a micro-file, you are never going to ruin anything, but it will take forever to complete the job

 

[chrisb]

Matt - of course that was silly - I mean, after 4 pages isn't the most practical approach self-evident?


Oh, wait - this is DIY ....

 

[scottjoplin]

What's the betting he still hasn't done it?