Cutting rectangular holes?

[fried1765]

I have a bunch of Greenlee chassis punches left to me by my father. Wonderful things; I would recommend them, but I just looked up the current pricing! But they'll do the trick, in a very easy and professional looking manner.

Rectangular Greenlee punches? I have a round set, and they certainly are wonderful, but didn't know that they came in rectangular form also.

 

[WranglerX]

I can't post a pic because I do not have them hosted anywhere and this site will not pull them from my computer.

Site will upload pictures from you computer, you are probably not following procedure correctly or not not using proper picture format (JPG-GIF-PNG)...

Dale

 

[NoTrespassing]

For .060 aluminum and only one part, I would just buy a set of jewelers files. Drill the hole first and file out the corners. Everybody should have a set of these files anyway. They're cheap and very useful.


Amazon.com: 24 Needle Files Jewelers Watchmakers Metal Filing Tools

Kevin

 

[davedj1]

The coping saw would be easier to control. Don't have one but am sure they are inexpensive.

Stanley 15-14 Fatmax Coping Saw - - Amazon.com

 

[Egon]

Hole saw for circular.

Square, drill corners and use dremel. Clamp a piece of steel on the cut line for a guide.

Make use of patience and time for better results.

 

[MossRoad]

Get a hand powered nibbling tool. I used to install car stereos back in the 70s-80s for extra cash. They work great for making square and rectangular hole. Draw the line where you want the hole. About 1/4" in from the edge, drill a hole that'll fit the nibbler head through, usually 1/4" hole. Then insert the nibbler head, and start nibbling! :laughing: Works great! :thumbsup:

Nickel Plated Nibbling Tool

 

[MossRoad]

Oh, yeah, the nibbling tool is usually around $15. A great value, and it'll last for years, always handy to have around in your toolbox.

 

[PILOON]

Nibbling tool and 'nibble' a tad undersize then finish with good single cut file.

'Back then' I custom made lots of aircraft instrument panels, that's where I learned lots of patience. LOL.
As time progressed I acquired many special power punches, some rounds and some rectangular for specific instrumentation.

For many rounds I used a fly cutter in the press drill.

Another trick is to use core drills or bell drills to remove the larger areas and finish with files or the chassis nibbler as shown earlier.

 

[MossRoad]

Yep, finishing off with a file works great if you don't have trim or an overlapping bezel on the device you are installing. Most of the time, the device is larger than the hole, and you don't have to be exactly accurate. Just be sure and check before starting to determine the level of accuracy you need.

 

[Doofy]

Ditto on a "Nibbler". Great for many different projects.