[R-390] Holy terror

[Shoppa, Tim]

Unibit style step drills (possibly with an extension shaft) will work great for the round holes. Yeah there's still chips that fly off but in aluminum, a good sharp Unibit will often make stringy chips that are fairly easy to get out.

For really large diameter holes in sheet metal, a hole saw works quite nicely, but I think you're probably working too small to think about that. There is one exception I know, there's a tool called a "spot weld hole saw" which is a tiny little hole saw designed especially for clean cuts in sheet metal. Great way to make corners for square holes (hint, hint).

As to square holes... if a hand nibbler won't reach (try both the Radio-Shack and Adel styles, heads are shaped differently and sometimes if one won't work, then the other will), there are very narrow head electric pneumatic nibblers (not cheap but a joy to use, if you can somehow angle them into an already populated chassis!). Don't forget, there's always the cold chisel. With skill and a proper backing, a cold chisel can produce edges superior to any of the other methods.
________________________________________
From: r-390-bounces at mailman.qth.net [r-390-bounces at mailman.qth.net] On Behalf Of Rasputin Novgorod [priapulus at yahoo.com]
Sent: Saturday, March 05, 2011 2:40 PM
To: R-390 at mailman.qth.net
Subject: [R-390] Holy terror

I have to put several holes, round and rectangular in
an old chassis about inch size. I do have two chassis
punches, but the wrong sizes. In the past I've tried
drawing the hole onto the metal, then drilling, filing
and power jigsawing to the lines.

I also have a dremol tool.

Any suggestions about doing this? It's a populated chassis
and I don't really want to spray steel filings and chips
all over it; nor do I want to have to dissassemble
too much.

Perhaps some kind of compact, powerful nibbler?


Sincerely
/b



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