I've bought a Jaycar 2U metal rack enclosure for an amplifier project I'm building. What's the best way to cut nice clean holes in it for the switches and sockets that are going on it? Also I need to cut some ventilation slots front and rear, any suggestions? Thanks,
David
hi, i f the switches are small, use a drill. if they are bigger u can use a hole saw cutter. or use a sheet metal nibbler.: altronics : Sheetmetal Nibbling Tool T2355 $22.95
mark
Drill hole(s) and file them out square, for neat round holes, you can drill the hole slightly smaller than needed and then ream it out to size.
Or you can use the nibbler tool as suggested by mark. Be careful with nibblers on steel that is thicker than specified, they break very easily.
You can also buy "chassis punch sets" that are used to make holes up to about 32mm in steel. aluminium etc. DSE USED to sell these years ago, and they worked well.
If you want to do vent slots in ALUMINIUM, a router can be used, be very careful and take it slowly, you will be surprised at how well it cuts. It will be very messy though, you will end up with little thin aluminium flakes everywhere. (A laminex trimmer with a suitable blade may work too - but I havent tried this)
If you have a triton bench with the router table attatchment, you have it made !
You can sand/file down any sharp edges afterwards.
Make practice cuts on scrap material first. Use on aluminium only. Due to the fact that thin metal can cut into you much easier than wood if it goes flying, use safety gear, clamp everything down well, and don't try this unless you are already experienced with using routers.
If you are happy with a round ventilation hole for (say) a fan, you can use a hole saw at a slow speed, or a jig-saw with a suitable metal cutting blade.
Obviously drill small holes, up to 6 mm diameter or so. I've found step drills to be excellent for enlarging holes in sheet metal, up to 30 mm or so - cleaner result than a hole-saw and far more controllable than larger twist drills or cone cutters.
Probably the only way to get really clean slots is using an end mill and some purchase those Chinese-made table-top milling machines to this end, but it can get expensive. There are companies that advertise online their services for manufacturing pierced panels in one-off and larger quantities. Otherwise, fabricate a template for the slot from four straight-edged pieces of sheet steel and countersunk screws or rivets, clamp that to the work piece and then drill/saw/file away until the slot matches the template.
If you want louvres, buy a fly press and a louvre punch, or find a friendly workshop with this equipment.
Chris
If you're loaded (with money) square drills can be had
yeah, tungsten carbide woodworking tools cut aluminium really well, the aluminium is soft and conducts heat well enough that the tool doesn't overheat. tends to get noisy though.
hole saws tend to slop when used on sheetmetal and you get a knife-edge. A drill-press or backing block attached to the work could help.
offset aviation snips are great for round holes in thin-enough sheet down to about 75mm diameter, but a cheap jigsaw will cost less (noisy though).
power-nibblers can be had too, either self-contasined or as a drill attachment.
Punch and die is the best way.
Graham
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