Cutting holes in aluminium enclosures

emperor · 22nd July 2007, 01:22 AM

Hi there

i know its a basic question for many amp builders, but im having a problem finding an FAQ, on cutting an Amp chassis, for, example, the iec scocket housing, and various other small apertures for the tidiest job in a DIY chassis.

Any guidance would be much appreciated. im very new to this

thankyou very much

Conrad Hoffman · 22nd July 2007, 02:50 AM

For round holes, I use an adjustable single arm circle cutter. Back the chassis up with wood and use clamps to hold it to the drill press table. Use slow speed. Don't do this with a hand drill. The basic manual method for all sorts of square and round holes is the nibbler. You drill a small hole (1/4 to 3/8 inch) and insert the tool, then squeeze the handle to remove a series of small bites in whatever direction you need to go. Somewhat tedious and you have to finish with a file, but it gets the job done without distorting the metal. The connoisseur of sheet metal work will own a variety of carefully chosen files. He will believe the files chosen by anyone else brand them as incompetent fools. I'd suggest four and six inch single cut mill files, and a variety of pillar files having no teeth on the sides- you use these to square up holes. OTOH, as the previous statement suggests, others will want something entirely different.

phreeky82 · 22nd July 2007, 06:54 AM

Non-round holes are the devil, I hate having to do those......but I outline the hole I need, and drill a series of small holes a bit inside the outline (i.e. room for error), then you can more or less push that middle section out, grab your files and get busy!

Thankfully I haven't had to make too make holes because it sure can take some time.

Juergen Knoop · 22nd July 2007, 07:11 AM

a fretsaw does fine in aluminium
regards

tvi · 22nd July 2007, 08:45 AM

These come in various shapes and sizes, very handy but can be expensive, UK brands to look for are Q-Max and Deltron.
Set-of-9-Greenlee-radio-chassis-punches-square-round

I picked up the greenlee IEC sized punch for about US$40 delivered to Aust a few months ago

Regards
James

22nd July 2007, 01:22 AM	#1
emperor diyAudio Member Join Date: Aug 2002 Location: Suffolk ,England	Cutting holes in aluminium enclosures Hi there i know its a basic question for many amp builders, but im having a problem finding an FAQ, on cutting an Amp chassis, for, example, the iec scocket housing, and various other small apertures for the tidiest job in a DIY chassis. Any guidance would be much appreciated. im very new to this thankyou very much

22nd July 2007, 08:45 AM	#5
tvi diyAudio Member Join Date: Apr 2001 Location: Moonee Ponds, Vic, Australia	These come in various shapes and sizes, very handy but can be expensive, UK brands to look for are Q-Max and Deltron. Set-of-9-Greenlee-radio-chassis-punches-square-round I picked up the greenlee IEC sized punch for about US$40 delivered to Aust a few months ago Regards James __________________ The small part of ignorance that we arrange and classify we give the name of knowledge. Ambrose Bierce

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22nd July 2007, 02:50 AM	#2
Conrad Hoffman diyAudio Member Join Date: Mar 2007 Location: Canandaigua, NY USA	For round holes, I use an adjustable single arm circle cutter. Back the chassis up with wood and use clamps to hold it to the drill press table. Use slow speed. Don't do this with a hand drill. The basic manual method for all sorts of square and round holes is the nibbler. You drill a small hole (1/4 to 3/8 inch) and insert the tool, then squeeze the handle to remove a series of small bites in whatever direction you need to go. Somewhat tedious and you have to finish with a file, but it gets the job done without distorting the metal. The connoisseur of sheet metal work will own a variety of carefully chosen files. He will believe the files chosen by anyone else brand them as incompetent fools. I'd suggest four and six inch single cut mill files, and a variety of pillar files having no teeth on the sides- you use these to square up holes. OTOH, as the previous statement suggests, others will want something entirely different.

22nd July 2007, 06:54 AM	#3
phreeky82 diyAudio Member Join Date: May 2003 Location: Townsville, Australia	Non-round holes are the devil, I hate having to do those......but I outline the hole I need, and drill a series of small holes a bit inside the outline (i.e. room for error), then you can more or less push that middle section out, grab your files and get busy! Thankfully I haven't had to make too make holes because it sure can take some time.

22nd July 2007, 07:11 AM	#4
Juergen Knoop diyAudio Member Join Date: Jan 2007	a fretsaw does fine in aluminium regards